parametric and automatic navigation process for electrode...

PARAMETRIC AND AUTOMATIC NAVIGATION PROCESS FOR ELECTRODE DESIGN

Wen-Ren Jong, Yu-Wei Chen and Pei-Hsuan Hsieh

Department of Mechanical Engineering of Chung Yuan Christian University, Chung-Li, Taiwan

Abstract In the mold design process the electrode is designed in

advance for a contour requiring high accuracy or for a complex contour. The mold material, fixture specification, and the working ability of electrical discharge machine are all considered in the design process; otherwise, there will be inaccurate positioning and poor machining accuracy. Therefore, to increase mold machining accuracy, the information of design and manufacturing stages must be integrated in order to prevent the design and manufacturing planning stages from mistakes, to solve problems, and to transfer information to the manufacturing stage effectively. In this study the redevelopment of the navigation process for electrode design of electrical discharge machining (EDM) is based on a computer-aided design (CAD) software, under the concept of design for manufacturing (DFM). The regions requiring EDM are listed for the engineer by using the feature recognition method according to the feature specifications. The machine working ability and material information integrated in the process can guarantee the manufacturability of electrode design, reduce the error rate of electrode design, and shorten the design time by over 70%.

Introduction With the rapid development of industrial technology in

recent years, the development of molds and the time it takes to make them have been shortened dramatically. A mold contains numerous parts, its machining method and process are complex, and mold making planning is mostly under the charge of senior engineers. For specific part features, milling, EDM, or a drilling process is used. The appropriate processing parameters are set up to aim for a short time and low material cost. The principle of EDM is completely different from traditional machining. The design process of electrode and processing parameters depends on the engineer’s expertise very much. Therefore, the design often has errors and failures due to human misrecognition, delaying the overall development time.

In terms of research on design and machining, Ho et al. [1] divided EDM into a processability indicator, effect of processing parameters, and electrode design and manufacturing methods for a discussion. The results showed that for the complex parameter relationship, different optimization methods were the key factor that determined the overall machining efficiency. Puertas et al. [2] used the Taguchi method to find out the first influence factor in the average roughness Ra and square root roughness Rq in the EDM process and then employed a

regression technique to deduce the trend. The results showed that the discharging current strength was the first influential factor. Good arc stability could reduce the surface roughness effectively under an appropriate current. Amorim et al. [3] utilized AISI P20 die steel as a processing object and discussed the material removal rate and surface roughness according to the polarity, current strength, and discharge time of different electrodes. When the polarity of the electrode was negative and the material was graphite, the results presented that high current strength and long discharge time led to a relatively high material removal rate. The optimum surface roughness was obtained when the electrode was negative and the material was copper. Pellicer et al. [4] discussed the differences in the section geometry and machining shape accuracy of an electrode and found that at the same electrode wear rate, the smaller the included angle of section edge was, the lower was the shape accuracy after machining, and multiple electrodes must be used for implementing the specified machining contour. O’Driscoll [5] indicated that considering the problems in the initial stage of design or judging potential problems before modeling could shorten the development cycle and reduce the overall development cost effectively. The previous literature has indicated that it is necessary to integrate electrode design with machining message chaining.

In terms of the research on CAD, Mahajan et al. [6] proposed a theory of developing an electrode design supporting system based on the EDM knowledge. The simulation verification showed the workability of electrode could be enhanced, but there was no workable system. Lee et al. [7] developed an electrode division method, whereby the discharge region selected by the user could be designed as an electrode suitable for different processing sequences automatically. Ding et al. [8] set up a computer-aided electrode design system, integrated with machining information, which assisted the designer to complete the electrode design rapidly and generated the fixture automatically. The paper also emphasized the importance of the position relation between the fixture and electrode (tool), but the discharge region should be determined by the designer. Pullan et al. [9] used the concept of concurrent engineering to integrate the model information and related manufacturing knowledge into the mold development process, contributing to increasing the overall development efficiency. Chen et al. [10] utilized the hint-based approach of feature recognition to automatically find out the narrow deep region unavailable for Computer Numerical Control (CNC) machining.

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There have been some computer-aided electrode design tools on the market, and previous literature has conducted related research, but the identification of the discharge region still depends on the designer. It is likely to miss the features requiring EDM, resulting in difficulty or errors in subsequent processing. Moreover, the design parameters are not integrated with the manufacturing information effectively, and the consideration of manufacturability is insufficient. As such, this study integrates the mold making navigation process architecture built by Jong et al. [11] with the processing parameters for electrode design to provide the user interface. In the model checking phase, the hybrid electrode feature recognition technique is used to screen out the electrode features, and the feature positions and contour information are recorded in the database. In the parameter design stage, when the processing parameters are set, the stages of EDM for different machining features is recommended, and the processing parameters and material information of various machining stages are given seamlessly. In the detailed design stage, the electrode is built automatically according to the preset information, replacing complicated manual operations, increasing design efficiency, and making the design more applicable to machining.

Research Technique Background In the product and mold design process, the technical

limitations and characteristics of the mold making stage must be considered, such as machine precision, machine efficiency, and cutter size. The design mode is determined according to these limitations and characteristics. If the importance of manufacturability is neglected, then it is likely to consume more material and time costs during mold machining. Among numerous processing modes, the parameters controlling for EDM are more complicated than any traditional machining principle. In order to improve the efficiency and quality of electrode design, this study develops an automatic navigation process for electrode design based on Three-tier Architecture [12][13]. The manufacturing ability and related material information are collected in advance and imported into the standard process after parametric integration, so that the user can obtain the manufacturing and machining information while designing the electrode, thus increasing the overall development efficiency. The embedded browser of CAD software is used for electrodes design, and the project managers and clients on the Internet can log into the system to monitor the project schedule and communicate on the design result. This platform is based on the CAD extensively being used by mold developers to implement a seamless integration of project management, design navigation, and knowledge management.

Pro/Web.Link [14] As the design of an electrode for EDM involves many

highly repetitive operations, programmed automatic processing can replace the tedious process of manual

operation. With the surface information grown from the electrode base as an example, the CAD has provided a corresponding tool, but multiple clicks are still required in order to obtain results. The Pro/Web.Link is used to compose the recognition tool directly, and the program can find out the appropriate surface according to the recognition condition and calculate the projected area. Finally, the system decides the appropriate electrode (tool) size automatically, as shown in Figure 1. Thus, the product design schedule is accelerated, and the misrecognitions resulting from manual operation can be reduced. The corresponding function can be found by the Guideline manual of the system program, programmed into an automation function.

Figure 1 Function of surface recognition

Electrical discharge machining The principle of EDM is different from a traditional

method that uses the cutting force of an inserted tool for machining. It uses the local high temperature generated by the discharge between two poles to cause evaporation melting of the surface between the electrode (tool) and workpiece, and the molten part of material is removed by the impact force of gasification and dilation generated in the discharge process. As the discharge frequency for the workpiece is tens to hundreds of thousands of times per second, each discharge column generates a crater. In order to evaluate the EDM state and quality, the processing rate (W), wear rate of electrodes ( ε ), machined surface roughness (Ra), and machining gap (C1 2) are taken as main evaluation criteria. Therefore, in parameter design, this study employs the rules of thumb concluded by Dong [15], where the function is represented mainly by discharging current (Ip), discharging current impulse duration (τon), and impact coefficient (D). The variation trend between processing characteristics and parameters are deduced and expressed as relationships. Equations (1) to (8) are the parameter relationships in the operating environment where the common copper and graphite for EDM are used as electrode material and the machining current is lower than 50A.

For the copper electrode: W≅0.0097·Ip

1.5·D (1) ε≅1.5· Ip

1.74 τon1.35 (2)

Ra=0.4·Ip0.43· τon

0.38 (3) C1 2=3.7·(4·Ra)0.9 (4)

For the graphite electrode: W≅0.015·Ip

1.5·D (5) ε≅ 800 Ip

0.33 ·τon0.93 (6)


Ra=0.275·Ip0.44·τon

0.42 (7) C1 2=10·(4·Ra)0.64 (8)

The application of EDM mostly uses more than one electrode, progressively machining from strong to weak. Therefore, the expected shape accuracy can be reached faster, so as to shorten the overall machining time effectively. The electrode (tool) size is designed in three stages, generally divided into rough machining, rough finishing, and finish machining.

Rough Machining Design The processing rate is given priority in the rough

machining stage. The electrode block is designed according to the electrode material at a high material removal rate and under the processing parameters. In terms of electrical discharge machine, according to the work capacity of the electrical control system on the machine tool and the processing characteristics of the electrode material, appropriate impulse duration (τon) and discharging current (IP) are selected for machining. In the discharge parameter design, with the same impulse duration and discharging current, the graphite electrode has a higher processing rate and lower electrode consumption than copper electrode. In terms of polarity selection, when the polarity of graphite electrode is negative, the processing rate is better than positive polarity. Therefore, the graphite electrode with negative polarity is given priority in the rough machining stage. As the working area has a great effect on the processing rate, when the working area is too small or too large, the overall processing rate decreases. As shown in Figure 2(a), when the working area is small, the machining condition of low surface roughness can increase the overall processing rate to the contrary.

Figure 2 Trend map of processing parameters [15]

In the rough machining stage the machining efficiency is the best when the ratio of the average current supplied from the power box to the working area is about 5 A/cm2 [15]. The design of impulse duration is shown in Figure 2(b). In the case of a fixed impact coefficient, when the impulse duration is too short or too long, the processing rate decreases. In addition, the discharging current (Ip) has a relatively steady processing rate when the impulse duration (τon) is between 10 and 100. Therefore, the mean of the interval is used as the impulse duration design value for this rough machining stage. After the aforesaid parameter

design, the processing rate, surface roughness, and discharging gap values are obtained from Equations. (5), (7), and (8), and the electrode (tool) for rough machining is designed.

Rough Finishing Design [15] The surface roughness is represented by the CH

(Charmilles) value specified in the surface roughness standard scale made by Verein Deutscher Ingenieure (VDI) VDI-3400. The relationship between the CH value and Ra (µm) is expressed as Equation. (9).

CH = 20 log10 (10 · Ra) (9)

In the discharge process, the electrode (tool) and workpiece surface are consumed to some extent, so that the difference between the CH values of the successive discharge of two electrodes is less than 15. If the difference between the rough machining and expected CH values exceeds this value, or the expected surface roughness (Ra) is 0.4µm to 1.6µm, then it is necessary to design rough finishing, as the fundamental purpose is to make the gap between the CH values before and after trimming smaller than 15. In the rough finishing stage, the surface roughness is designed based on the machining CH value of rough machining minus 15. As the purpose is to trim the roughness, the impulse duration is the same as that for the rough machining stage, but the discharging current and average current are set by reducing the machining strength supplied from the power box by one level and referring to the rough machining stage. In terms of electrode material, cathodic graphite with its good processing rate is given priority. The processing parameter definition of the rough finishing stage is completed by the aforesaid condition setting, and the electrode (tool) for the rough finishing stage is designed according to the parameters of the processing rate, surface roughness, and discharging gap obtained from Equations. (5), (7), and (8).

Finish Machining Design In the finish machining stage, the specific shape

accuracy and surface roughness of the features to be machined are taken as the ultimate objective for designing discharge parameters. Low strength discharging current is used for the operation to avoid any higher pulse damaging the workpiece surface fineness. Therefore, the discharging gap must be shortened when the discharging current is low, so that the electrode can easily connect the workpiece for a smooth discharge. As the shape accuracy of the electrode must be maintained in the course of working, the selection of electrode material should aim at material with a low electrode wear rate under the working condition of low machining strength. As shown in Figure 3, copper and copper-tungsten materials have low electrode consumption under low surface roughness, but copper-tungsten material has a higher cost than just copper. Therefore, if the processing objective is not high temperature cemented carbide, then the copper electrode can be considered first.


In terms of parameter design, the impulse duration is half as large as the design value of the rough machining stage according to the designer’s experience, so as to define the impulse duration design value of the finish machining stage and matching the final surface roughness. The discharging current (IP) is deduced from Equation. (3), and the final surface roughness is substituted in Equation. (4) to obtain the design value of the discharging gap. The electrode (tool) for the finish machining stage is designed according to the aforesaid discharge parameters.

Figure 3 Processing characteristics of various electrode materials at the same wear rate [15]

User-Defined Feature (UDF) UDF is used to reproduce the feature group in the same

shape. Some common features in product design are packaged as a UDF file, and this file is given the required reference and parameters that can be conveniently used in design, so as to shorten the design time. When the electrode base is built by UDF, after the reference and size are set according to prompting, the feature can be rapidly established. This study uses the system program function and UDF to establish an automatic feature generation function, in which the conditions and values of geometric reference are given, and the target feature can be created quickly.

Discharge Feature Recognition and Electrode Design

This study develops the navigation process for an electrode design under the concept of DFM. First, different EDM features are classified by a geometric feature recognition algorithm, and then the user designs the electrode through standard, parametric, and automatic process steps. This process pays attention to the relationship between design and manufacturability, so that the designed electrode part meets the quality requirement, design error is prevented, and design efficiency and mold machining accuracy are increased.

Parametric and Automatic Design In order to effectively integrate the machining

requirement, fixture specification, and machine parameters with the design process, the electrode (tool) size is normalized, the size relationship between various data is defined by relations and parameters, and the defined electrode features are packaged as a UDF file. The design and manufacturing information can be connected rapidly

by the definition procedure, and there will not be any errors in the design size. In the subsequent electrode design process, the corresponding UDF is called by the system program, and relevant parameters are set, allowing the electrode to be designed automatically.

Hybrid Discharge Feature Recognition The slot feature with an undersize square corner and a

fillet angle in the workpiece, or the hole with an oversize aspect ratio and special requirement for surface accuracy is usually machined by EDM. Therefore, it is used as the basis of search in this study to enhance the feature recognition technique developed by Jong et al. [11]. The graph-based template of discharge feature is then derived, and the region to be machined is searched. For the blind-slot and blind-step, the bottommost surface of the model machining feature is captured by the system program, defined as the initial surface. The two diagonal points of the initial surface and adjacent construct surface are next identified. If they are greater than or equal to the two points of the manifold edges of the adjacent initial surface, then it is a concave edge feature; otherwise, it is convex edge, as shown in Figure 4. The construct surface with a common edge as a concave edge is captured, the geometric elements are stored in array, and the defined graph-based template is compared with the rule-based approach. When there are three concave edges and one convex edge and four construct surfaces are adjacent, the formed feature is a blind-slot, as shown in Figure 5(a). The feature formed by two concave edges and two convex edges and four construct surfaces that are adjacent is a blind-step, as shown in Figure 5(b).

Figure 4 Concave edge recognition method

Figure 5 Pattern-based template of discharge feature

In terms of internal dent feature, the point coordinates of the internal contour and adjacent surface are captured. When a diagonal point in the adjacent surface is lower than the point coordinate of the internal contour, it is regarded as being a concave internal contour feature, and the rule-based approach is used to distinguish through and non-through features. As shown in Figure 6(a), when two internal contours ( ic1 and ic' ) have shared adjacent surfaces (f1 and f'), this is regarded as a through feature. When there is only one internal contour (ic(1) and there is


no shared adjacent surface, then it is a non-through feature, as shown in Figure 6(b).

Figure 6 Classification of through and non-through features

The internal contour is subdivided into hole and non-hole features. This study uses the hint-based method and List Contours of the system program to capture the number of edges of an internal contour. The contour formed by two semi-circles is a hole feature. The contour formed by more than two edges is a non-hole feature. The classification of an internal contour is shown in Figure 7. For the internal contour of non-through, if it is hole feature, then the characteristic diameter (R) and depth (L) are captured to calculate the aspect ratio. When the aspect ratio is greater than 5, EDM is recommended for cutting. If it is a non-hole feature and the contour is formed of straight lines, then EDM is also recommended. The Wire Electrical Discharge Machining (WEDM) is recommended for machining the internal contour of through feature.

Figure 7 Classification of internal contour

Navigation Process for Electrode Design The planning and design process of DFM is divided

into model analysis and electrode design. First, the discharge regions are listed by using the aforesaid hybrid discharge feature recognition method, to avoid the designer missing the region requiring an electrode block. Afterwards, the designer designs the electrode block through the parametric, automatic, and standard process steps. The process connects the manufacturing information to the model properties in series, so that the designed electrode block meets the production requirement, and the design information can be stored effectively, which are applied to the output of Bill of Materials (BOM).

Model Analysis When the model is imported, its geometric features are

obtained by the system program function. Next, the features requiring discharge are filtered by the hybrid discharge feature recognition method, classified according to the feature information, and a webpage-based feature information list is generated. The webpage-based list can highlight the corresponding features by functional

operation, reminding the designer of recognized discharge features. When the designer decides on the discharge feature to be made, the system integrates the feature type, geometry, center point coordinates, and discharge surface area into the database for subsequent automatic construction of the electrode block. The case studies will further show the details of model analysis.

Electrode Design

This study employs the UDF, relations, and parameters for control. The electrode design process incorporates to the machining information, so that the electrode is applicable to the EDM process. The electrode design process is divided into the parameter design stage and detailed design stage. In the parameter design stage, the designer decides the EDM parameters in order for the system to calculate the appropriate electrode design mode. The detailed design stage is divided into two parts. One is the characteristic dimension design of the electrode (tool), and the other one is the electrode base size design for the fixture grip.

Parameter design stage In the process planning and design, the machine

information and material information are parameterized and built in the database. Thus, the number of stages for machining the discharge region can be estimated according to the expected surface roughness and the current supplied by the machine tool. First, cathodic graphite is preset as an electrode material in the rough machining stage, and the CH value of surface roughness is calculated. When the difference between the CH value of rough machining (CHRe) and the expected CH value (CHFe) is smaller than 15, the stage number of EDM is recommended as two, i.e. rough machining and finish machining. If the CH value difference is greater than 15, then the system calculates the frequency of rough finishing by rounding in units of 15. When the designer determines the total number of machining stages, the system can list the recommended electrode materials and polarity for various stages, and the designer can modify with more appropriate parameter values. The confirmed machining information will be stored in the database to complete the parameter design stage. The design and machining conditions can be integrated by predetermining the machining information, so as to avoid insufficient times in the machining stage and inappropriate electrode material resulting in inaccurate machining.

Detailed design stage This stage lists the recommended rough machining,

rough finishing, and finish machining information for parameter design stage according to the information recorded in the database, such as the feature information and the processing information, and then the electrode state is displayed. After a standard and parametric definition of the electrode, the machining information can be integrated


with the definition of electrode size. Therefore, the electrode for the machining stage can be created automatically.

In the automatic electrode design process, as the position coordinates of feature and contour information have been recorded in model analysis, the system program can easily target the recognized electrode feature and generate enough volume block. The electrode (tool) features are divided into discharge region and extension region, as shown in Figure 8. The discharge region uses the concave surface feature to shape the appearance according to the recognized feature of the workpiece. The required discharging gap is calculated according to the material and polarity defined in the parameter design stage with the desired accuracy. The extend length of the electrode is determined by comparing the size of the discharge region with the cutter size for the NC machining.

Figure 8 Relation between electrode and workpiece

The design of the electrode base aims to match the fixture size for the fixed electrode in the electrical discharge machine, so that the electrode will not offset or fall off due to any shaking in the discharge process. In the base size definition, in order to prevent interference between electrode (tool) features and to reduce the overall electrode material consumption, the Z-direction projected area of the electrode (tool) feature is taken as the basic minimum size, and the closest fixture size larger than the projected area is taken as the selection condition. The standard fixture specification is searched from the preset manufacturing database, and then the size of the electrode base is determined. The system program calls UDF to generate feature with size parameters to implement the automatic base construction.

In the automatic electrode construction process, the discharging gap generates a step between the electrode (tool) and blind-step discharge feature, as shown in Figure 9, as such the outward surface with a step on the electrode (tool) feature must be extended. This step uses the system program function to capture the normal vectors of the electrode (tool) quilt, as compared with the normal vectors of the current discharge feature quilt, as shown in Figure 10. As the highest plane is required for the electrode base, F′6 is excluded directly. When there is no corresponding negative vector, the extension plane feature is established automatically based on the characteristic surface of step direction (F′5), so as to complete a reasonable electrode.

Figure 9 Procedure of repairing a step between features

Figure 10 Step matching of the discharge feature

Case Studies This section discusses the research results, in which

the complete process of an actual case is demonstrated, the time consumed and the number of clicks are recorded, and the design efficiency in the case with a navigation process is compared with that without a navigation process. The case is the core design of a plastic mold, as shown in Figure 11. The discharge features include blind-slot, blind-step, through slot, and through hole.

Figure 11 Case model

Electrode Design

In terms of model analysis, the system uses the imported model to detect the discharge feature. The machining features are then classified and listed, as shown in Figure 12. When the user confirm the feature for electrode design, the system stores the related information of the current feature in the database for subsequent electrode design.


Figure 12 Model analysis stage

In the electrode design stage, as shown in Figure 13, the user defines the expected surface roughness as N7, which has reached the specification of rough finishing, but the current is set as 50A. Under the maximum machining strength, the difference between the rough machining and expected CH value has not exceeded 15, and so the stage number of EDM is recommended as three, and the recommended materials and polarities for various stages are then listed. When all the processing parameters are confirmed, the user can export the electrode model applicable to various machining stages. Taking the rough machining stage as an example, the maximum Ip(18A) and τon (50µs) are substituted in Equation. (7) to obtain the Ra (20.35 µm ), and C1 2 (0.13344mm) is calculated by Equation. (8). The electrode for the rough machining stage is now generated automatically by the parameters. Error! Reference source not found. lists the specifications of electrode parts for various stages. For this case model, the blind-step and blind-slot features with corresponding rough machining, rough finishing, and finish machining electrodes are created.

Figure 13 Electrode design stage

Table 1 Processing parameters for various stages Expected surface roughness (Ra): 1.6µm

Power supply specifications: 50A Mold material: Steel

Machining stage: Rough machining

Ip: 18(A) τon: 50(µs)

Electrode material: Graphite Polarity of electrode: -

W: 1.0607(g/min) Ra: 20.35(µm)

C1/2: 0.13344(mm)

Machining stage: Rough finishing Ip: 9(A) τon: 50(µs)

Electrode material: Graphite Polarity of electrode: -

W: 0.3750(g/min) Ra: 15.00(µm)

C1/2: 0.11180(mm)

Machining stage: Finish machining Ip: 0.35(A) τon: 25(µs)

Electrode material: Copper Polarity of electrode: +

W: 0.0012(g/min) Ra: 1.6(µm)

C1/2: 0.01967(mm)

Efficiency Comparison

The design processes of three users were recorded and averaged to compare the efficiencies with and without the navigation process, as shown in Table 2. In the case without the navigation process, the user shall import the model, open the assembly file manually, identify the feature requiring EDM, and then measure the characteristic dimension and position. The electrode discharge area, electrode extension, and electrode base design are implemented manually according to the required size for the current machining stage, so as to complete an electrode model. Each electrode of the other discharge regions is produced repeatedly in the same way. Using the navigation process for the electrode design developed in this study, in the model importing stage, as long as the model to design electrode is selected, the system creates the assembly file automatically with the project name, integrates it into the model, uses feature recognition to assist the user to find the model discharge region, and guides the user to input the supplied current, the expected surface roughness, machining frequency, and machining information at various stages. The system calculates the discharging gap for various stages according to the machining information and builds the electrode model automatically, so as to complete the electrode for various machining stages of the current feature. The design time can be cut by 76.1%, and the number of clicks can be reduced by 54.2% with navigation process. In addition, the manufacturing information is incorporated in the design process, so that


the design is applicable for machining, and the error rate can be reduced.

Table 2. Efficiency comparison of case study Test object

Test item

Without navigation system With navigation system

Time(min) Number of clicks Time(min) Number of

clicks Model import 2 15 1 3 Model checking -- -- 3 9 Electrode design 86 450 17 201 Total 88 465 21 213 Reduced by -- -- 76.1% 54.2%

Conclusion The navigation process for electrode design developed

in this study uses the hybrid discharge feature recognition method, in which the region requiring EDM in the model can be identified rapidly, so as to avoid human misrecognition that causes difficulties in machining. The feature information can be saved during recognition and integrated with the design parameters of the electrode, so that the process is more likely to be automated. In terms of automatic electrode design, the system can recommend the electrode material and the number of machining stages according to the discharge machine parameters and the expected surface roughness set by the designer. For the standardized and parameterized electrode size, during the automatic design process the recommended values can be converted into parameters integrated into the design, so that the electrode is more applicable to machining and to avoid faulty design resulting in inaccurate machining or errors. According to the case discussion in this study, the electrode designed with the navigation process can significantly shorten the operating time and reduce the number of clicks, thus effectively increasing overall design efficiency.

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