MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MAJOR: MACHINE MANUFACTURING TECHNOLOGY RESEARCH AND DESIGN A VIBRATION-ASSISTED ELECTRICAL DISCHARGE MACHINING USING FLEXIBLE MECHANISM INSTRUCTOR: PHAM HUY TUAN STUDENT: HOANG MINH THANG TRINH VU NGUYEN LONG NGUYEN TIEN TRUONG Ho Chi Minh city, July 2024 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION GRADUATION PROJECT RESEARCH AND DESIGN A VIBRATION-ASSISTED ELECTRICAL DISCHARGE MACHINING USING FLEXIBLE MECHANISM Major: MACHINE MANUFACTURING TECHNOLOGY Advisor: PHAM HUY TUAN, Assoc. Ho Chi Minh City, July 2024 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATONNAL EDUCATION GRADUATION PROJECT RESEARCH AND DESIGN A VIBRATION-ASSISTED ELECTRICAL DISCHARGE MACHINING USING FLEXIBLE MECHANISM Major: MACHINE MANUFACTURING TECHNOLOGY Advisor: PHAM HUY TUAN, Assoc. Ho Chi Minh City, July 2024 Faculty of International Education - Ho Chi Minh City University of Technology and Education HCMC UNIVERSITY OF TECHNOLOGY THE SOCIALIST REPULIC OF AND EDUCATION VIETNAM FACULTY OF INTERNATIONAL Independence – Freedom – Happiness EDUCATION CAPSTONE PROJECT ASSIGNMENT Advisor: PHAM HUY TUAN, Assoc. Students ‘s name: Hoang Minh Thang Student ID: 20143209 Students ‘s name: Trinh Vu Nguyen Long Student ID: 20143222 Students ‘s name: Nguyen Tien Truong Student ID: 20143213 1.
Project title: RESEARCH AND DESIGN A VIBRATION-ASSISTED ELECTRICAL DISCHARGE MACHINING USING FLEXIBLE MECHANISM 2. Initial material provided by the advisor: − PZT actuator: P-225.10 PICA Power Piezo Actuator 3. Content of the project: − Research has been conducted on the principles and characteristics of Electrical Discharge Machining (EDM) as well as the principles of vibration-assisted machining methods. Additionally, studies have focused on exploring the structures and design principles of vibration-assisted tools that are integrated into the electrode holder of EDM machines.
Expected products: − Capstone report − Design drawings 5. Date of assignment: 6. Date of submission: 7. Presentation language: The report: English Vietnamese Presentation: English Vietnamese DEAN HEAD OF DEPARTMENT ADVISOR (sign with full name) (sign with full name) (sign with full name) Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education DISCLAIMER We certify that this graduation project is my own research that I implemented and studied on my own.
The data and figures presented in the report were cited and referenced source annotations. They are all true and trustworthy and this thesis has not yet been published in any prior research or studies. Ho Chi Minh City, (Sign with full name) Hoang Minh Thang i Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education ACKNOWLEDGEMENT Firstly, we would love to express my deepest gratitude to my instructor Assoc. Pham Huy Tuan and other lecturers, Dr.
Dang Quang Khoa and Dr. Nguyen Van Khien, for their consistent support and for providing us with helpful recommendations and valuable counsel. Thanks to these words, we have become much more mature students. We believe that the knowledge learned from those teachers helped us implement this bachelor’s thesis and reinforced our specialized knowledge, which will be invaluable for my not-too-distant future career.
In addition, we would like to sincerely thank Mr. Le Nguyen Hoang Tan, a master's student - the inventor of the vibration module, the person who allowed us to use it - the soul of this project and more we will never forget Mr. Nguyen Thanh Hai, a master's student- who accompanied the group on this journey and taught us about Solidwork and Ansys software. Last but not least, big thanks and appreciation to our beloved peers and classmates for their recommendations, cooperation, encouragement, and constructive contributions to the accomplishment of this thesis from beginning to finish.
Once again, thank you to all individuals who have gone through with us in this educational endeavor. Representative Student Hoang Minh Thang ii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education SUMMARY Project title: “RESEARCH AND DESIGN A VIBRATION-ASSISTED ELECTRICAL DISCHARGE MACHINING USING FLEXIBLE MECHANISM”. Electric Discharge Machining (EDM) is an extraordinary method that crafts conductive materials with unparalleled precision, achieved by harnessing the power of electric sparks dancing between an electrode and the workpiece, while enveloped in a captivating dance with a dielectric fluid. EDM holds a significant advantage when it comes to machining materials that possess hardness, brittleness, or intricate geometries.
However, several factors influence both machining time and surface quality post-machining. A noteworthy approach to enhance the EDM process lies in the utilization of Vibration Assisted Machining (VAM). Vibration Assisted Machining, a technique that involves the application of high-frequency vibrations with small amplitudes to a cutting tool, gracefully enhances the overall machining process. The thesis aims to describe the process of designing and fabricating a vibrational support mechanism for an electrode used in the electrical discharge machining (EDM) process.
The vibrational support mechanism for the electrode consists of a copper electrode, a flexure hinge mechanism designed based on a previous thesis, optimized with appropriate stiffness to transmit vibrations, an electrical power transmission system, and a pulse generator capable of generating controlled vibrations with specific amplitude and frequency. Furthermore, the thesis presents test parameters to verify the accuracy of calculations and optimize the design. Experimental trials were conducted to assess the performance of the design, including natural frequency oscillations, displacements, undesired displacements, and the structural rigidity of the design. Ho Chi Minh City, 3rd July 2024 (Sign with full name) Hoang Minh Thang iii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education TABLE OF CONTENTS DISCLAIMER.
iii TABLE OF CONTENTS. iv LIST OF ACRONYMS AND SYMBOLS. vii LIST OF FIGURES. viii LIST OF TABLES .2 The needs of the topic.3 Scientific and practical significance .4 Research’s objectives, scopes, approach and method .4 Research objectives and scopes .1 Introduction of Electrical Discharge Machining (EDM) .2 Classifications of EDM .3 Construction of Sink EDM machine:.
10 iv Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education 2.6 Advantages and disadvantages of EDM .2 Introduction of Vibration-assisted machining .1 Concept of Vibration-assisted machining .3 Classifications of VAM .3 Introduction of Vibration-assisted Electrical Discharge Machining .1 Concept of Vibration-assisted Electrical Discharge Machining .2 Compare traditional EDM with Vibration-assisted machining .4 Introduction of Piezoelectric .1 Classifications of Piezoelectric effect.5 Correlation between displacement and impact force .5 Introduction of flexure hinges .2 Fabrication of a Flexible Hinge .3 Advantages and disadvantages .6 Theory of natural oscillations .7 Apply using ANSYS software .1 Defining objectives and parameter .2 Introducing ANSYS Mechanical ADPL software .1 Fractional factorial design .9 Single Objective Optimization (GA). DESIGN OF VIBRATING TOOL (INHERITED). 33 v Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education 3.2 Modeling design ideas .4 Flexure hinge design.2 Optimizing the symmetric-zigzag flexure hinge.3 Design of Experiments .4 Genetic algorithm (GA) model .5 Design of other components .3 Electrical insulation components .6 Assembly the vibration module. INSPECTION OF THE VIBRATION MODULE.
CONCLUSION AND DEVELOPMENT ORIENTATION. 76 vi Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education LIST OF ACRONYMS AND SYMBOLS EDM Electrical Discharge Machining EDM Micro Electrical Discharge Machining VAM Vibration-assisted Machining VAEDM Vibration-assisted Electrical Discharge Machining WEDM Wire Electrical Discharge Machining MRR Material Removal Rate TWR Tool Wear Rate SR Surface Roughness PEA Piezoelectric Actuator GA Genetic Algorithm MC Monomer-Cast Nylon POM Polyoxymethylene DC Direct Current AC Alternating Current DOF Degree of Freedom DOE Design of Experiment FCCD Face-centered central composite design CCD Central composite design vii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education LIST OF FIGURES Figure 2. Die-sink EDM. Hole drilling EDM.
Types of VAM based on modes of vibration. Mechanism of VAM-equipped micro EDM. Comparison of the machining time in micro EDM. Surface morphology micro-milled.
Direct piezoelectric effect mechanism. Inverse piezoelectric effect mechanism. Branches of Piezoelectric materials. An application of piezoelectricity in inkjet printer.
Types of Piezoelectric Actuator. Design of a Piezo stack actuator. Main classes of flexure hinge. Types of flexure hinge.
Frequency response curve. Illustrated of mode shape. Flow chart of experimental model building. Central Composite Design.
Box–Behnken Design for 3-factors. Vibration module concept. Rectangular-parallelepiped-shape model. Disc-shape model.
Cylinder-spring-shape model. Zigzag-shape model. Zigzag-shape model with 3 joints. One-side-zigzag and Symmetric-zigzag model.
Symmetric-zigzag-shape model. Compliant mechanism’s parameters design in VAEDM. Local Sensitivity of parameter variables. Normal plot of the standardized effects for the frequency response.
42 viii Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education Figure 3. Normal plot of the standardized effects for the stress response. Normal plot of the standardized effects for the deformation response. Pareto chart of the standardized effects for natural frequency.
Normal plot of the standardized effects for natural frequency. Normal plot of the standardized effects for stress. Normal plot of the standardized effects for deformation. Goodness of fit.
Final results by Ansys. Flexure hinge design. Design of Body with flexure hinge mechanism. General design of the Vibration module.
Top plate design. Connecting shaft design. Retainer plate design. Connecting head design.
Contacting tip design. Assembling the vibration module. Vibration module mounted to a support base for displacement inspection. Displacement Inspection System.
Displacement inspection layout. 64 ix Faculty for High Quality Training - Ho Chi Minh City University of Technology and Education LIST OF TABLES Table 2. Technical data of Piezo P-225. Chemical compositions of 7075 Aluminum alloy.
Mechanical properties of 7075-T6 Aluminum alloy. Design parameters and survey ranges. Input parameters and value levels. Design of Experiments.
Input parameters and value levels. Final Design of Experiments. Evaluation of Genetic algorithm (GA) model. Objectives and constrained.
Results of FEM analysis. Specifications of PZT actuator. Specifications of modular high-power amplifier. Specifications of laser displacement sensor.
Details regarding the laser displacement sensor. Displacement capability corresponding to the input Voltage and. 65 x Faculty of International Education - Ho Chi Minh City University of Technology and Education CHAPTER 1.1 Introduction Modern industrial industries, especially machining technology, face increasing demands and pressures due to the introduction of cutting-edge machinery and equipment. Such complex and contemporary needs can no longer be satisfied by traditional machining techniques.
Consequently, a sizable variety of unconventional milling techniques have emerged, such as Electron Beam Machining (EBM), Plasma Arc Machining (PLM), Laser Beam Machining (LBM), and Electrical Discharge Machining (EDM). Consider the well- known genre of EDM. This method is widely used for machining hard, brittle metal in a variety of applications, including molds, cars, and airplanes. It nevertheless has certain unavoidable disadvantages, like a poor material removal rate and low finishing, despite its greater machining capabilities in a variety of metal types.
In order to address it, though, the current can be raised in order to lengthen the machining time; nonetheless, this may result in increased electrode wear rate and surface roughness. Consequently, vibration-assisted machining techniques have been developed to lessen these issues. We chose to do research on the topic of " Research and design a vibration-assisted electrical discharge machining using flexible mechanism " for our graduation thesis for the reasons outlined above. This subject has been the subject of numerous national and international investigations.1 Domestic researches EDM has been widely used in the metalworking industry and other sectors in Vietnam.
Here are some fields and applications of EDM in Vietnam: a) Machine Manufacturing Industry: EDM is used to process precise components in the machine manufacturing field, including cutting, drilling, turning, and grinding metal parts. b) Automotive Industry: EDM is applied in the processing of molds, die-casting, and precise components for the automotive industry.