This paper presents vibration characteristics of a wire cut discharge machine in which an electrorheological brake actuator is used to control the wire tension. On the basis of the tension level required in the machine an appropriate size of the ER brake actuator is devised. The ER brake actuator is then incorporated into the machine and the field-dependent wire tension is experimentally evaluated. The straightness of the workpiece is also empirically investigated by changing the intensity of the electric field. In addition, the tension control performance of the discharge machine is simulated by utilizing a robust sliding mode controller.
Get full access to this article
View all access options for this article.
References
1.
1. Dauw, D.F., Sthioul, H., Delpretti, R. and Tricarico, C.1989. “Wire Analysis and Control for Precision EDM Cutting,”Annals of the CIRP, 38:191-194.
2.
2. Magara, T., Yamada, H., Yatomi, T. and Kobayashi, K.1993. “Study on Improvement of Surface Straightness in Wire-EDM,”Journal of Japan Society of Precision Engineering, 54(4):619-624.
3.
3. Liao, Y.S., Chu, Y.Y. and Yan, M.T.1997. “Study of Wire Braking Process and Monitoring of WEDM,”International Journal of Machine Tools and Manufacture, 37(4):555-567.
4.
4. Guo, Z.N., Lee, T.C., Yue, T.M. and Lau, W.S.1997. “Study on the Machining Mechanism of WEDM with Ultrasonic Vibration of the Wire,”Journal of Materials Processing Technology, 69:212-221.
5.
5. Gökler, M.I. and Ozanözgü, A.M.2000. “Experimental Investigation of Effects of Cutting Parameters on Surface Roughness in the WEDM Process,”International Journal of Machine Tools and Manufacture, 40:1831-1848.
6.
6. Stevens, N.G., Sproston, J.L. and Stanway, R.1988. “An Experimental Study of Electro-Rheological Torque Transmission,”ASME Journal of Dynamic Systems, Measurement and Control, 110:182-188.
7.
7. Carlson, D. and Duclos, T.F. 1990. “ER Fluids Clutches and Brakes-Fluid Property and Mechanical Considerations,”Proceedings of the 2nd International Conference on ER Fluids, pp. 353-367.
8.
8. Johnson, R., Bullough, W.A., Firoozian, R., Hosseini-Sianaki, A., Makin, J. and Xiao, S. 1991. “Testing on a High Speed Electro-Rheological Clutch,”Proceedings of the 3rd International Conference on ER Fluids, pp.424-441.
9.
9. Choi, S.B., Cheong, C.C., Kim, G.W.1997. “Feedback Control of Tension in a Moving Tape Using an ER Brake Actuator,”Mechatronics, 7(1):53-66.
10.
10. Choi, S.B. and Park, D.W.1994. “Moving Sliding Surfaces for Fast Tracking Control of Second-Order Dynamic Systems,”ASME Journal of Dynamic Systems, Measurement and Control, 116:154-158.
