scholarly journals Sliding abrasive wear when combining WEDM conditions and polishing treatment on H13 disks over 1045 carbon steel pins

2021 ◽  
Author(s):  
Antonio J. Sánchez Egea ◽  
Vitaliy Martynenko ◽  
Alejando Simoncelli ◽  
Gil Serrancoli ◽  
Daniel Martínez Krahmer
Keyword(s):  
Surface Roughness ◽  
Surface Properties ◽  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Initial Surface ◽  
Friction Coefficients ◽  
Surface Conditions ◽  
Aisi 1045

AbstractForging dies are crucial in forging to manufacture accurate workpieces. These dies are generally made of AISI H steel series and hardened and tempered medium carbon alloy steel. Dies are processed by using high-speed milling + polishing or electrical discharge machining + polishing. The surface quality of the workpiece depends on the surface properties of these dies, where surface roughness, material hardness, and wear evolution of their surfaces are critical aspects to consider. This research analyzes different wire electrical discharge machining surface conditions combined with polishing treatment to describe their influence on friction and wear. Wire electrical discharge machining defines the disks’ surface properties in finishing and roughing conditions, and polishing treatment varies in time and paper sand depending on the roughness. Abbott-Firestone curves and Rsk-Rku roughness parameters characterize the surface roughness of each studied configuration. Room temperature pin-on-disk tests were performed to analyze friction coefficients and wear rate for AISI 1045 pins and AISI H13 disks. On average, the highest (0.284) and the lowest (0.201) friction coefficients were found for the combination of finishing wire electrical discharge machining + polishing and roughing wire electrical discharge machining conditions, respectively. Scanning electron microscope images were taken to describe the wear tracks and pin degradation for different sliding abrasive configurations. The diagram correlating the surface morphology and the friction coefficient predicts the wear damage on initial surface conditions, which is crucial in the forging industry to determine tool maintenance or replacement.

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

2021 ◽  
pp. 095440892110414
Author(s):  
TS Senthilkumar ◽  
R Muralikannan ◽  
T Ramkumar ◽  
S Senthil Kumar
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Box Behnken Design ◽  
Pulse On Time

A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

Surface Roughness at Wire Electrical Discharge Machining

2015 ◽  
Vol 760 ◽  
pp. 551-556 ◽  
Author(s):  
Oana Dodun ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Vasile Merticaru ◽  
Gheorghe Nagîţ
Keyword(s):  
Surface Roughness ◽  
Empirical Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Roughness Parameter ◽  
Wire Electrical Discharge Machining ◽  
Power Type ◽  
Surface Roughness Parameter ◽  
Pulse On Time ◽  
Pulse Off Time

Wire electrical discharge machining is a machining method by which parts having various contours could be detached from plate workpieces. The method uses the electrical discharges developed between the workpiece and the wire tool electrode found in an axial motion, when in the work zone a dielectric fluid is recirculated. In order to highlight the influence exerted by some input process factors on the surface roughness parameter Ra in case of a workpiece made of an alloyed steel, a factorial experiment with six independent variables at two variation levels was designed and materialized. As input factors, one used the workpiece thickness, pulse on time, pulse off-time, wire axial tensile force, current intensity average amplitude defined by setting button position and travelling wire electrode speed. By mathematical processing of the experimental results, empirical models were established. Om the base of a power type empirical model, graphical representations aiming to highlight the influence of some input factors on the surface roughness parameter Ra were achieved. The power type empirical model facilitated establishing of order of factors able to exert influence on the surface roughness parameter Ra at wire electrical discharge machining.

A New Technology to Machine Bimetal Band Saw

2016 ◽  
Vol 861 ◽  
pp. 9-13
Author(s):  
Hong Jian Dong ◽  
Qin He Zhang ◽  
Lei Tan ◽  
Guo Wei Liu ◽  
Tuo Dang Guo
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
New Technology ◽  
High Speed Steel ◽  
Processing Route ◽  
Grinding Process ◽  
Wire Electrical Discharge Machining ◽  
Low Carbon ◽  
Band Saw

As a kind of commonly used tools, junior hacksaw plays an important role in our daily life. A new kind of bimetal band saw taken low carbon medium alloy steel X32 as the backing material and the high-speed steel M42 as the saw tooth material is developed. In this paper, a new method to machine the bimetal band saw with wire electrical discharge machining (WEDM) is introduced. The processing route for common tooth profile is calculated. The fixture with specific angles is designed with CAD software (proe5.0) and machined with 3D printing technology. The experiments show that bimetal band saw machined with WEDM method has better surface quality compared with that machined through the traditional grinding process. Without any burrs, the new bimetal band saw is more resistant to wear and has a longer service life.

Wire Electrical Discharge Machining – High Speed VS Abrasive Waterjet - A Case Study

2011 ◽  
Vol 189-193 ◽  
pp. 4245-4255
Author(s):  
Shi Jin Zhang ◽  
Yu Qiang Wu ◽  
Yan Li Wang
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Wire Electrical Discharge Machining ◽  
Technological Advancement ◽  
Proper Selection ◽  
Regular User

Technological advancement, on the one hand, made Electrical Discharge Machining (EDM) much faster. One example of that is the presence of Wire Electrical Discharge Machining – High Speed (WEDM-HS) machine, which makes the material removal rate as high as 80 . On the other hand, it also made Abrasive Waterjet (AWJ) achieve much better quality surface and tighter tolerance. As a result, these two types of machining process have converged to the point where they can complement one another quite nicely in selected applications. However, it does not mean user may pick any one for their applications. The proper selection not only decreases the manufacturing costs but also achieves better quality. This paper focuses on comparing WEDM-HS with AWJ by actually cutting a special designed sample. Through comparison from several aspects which include dimension precision, surface roughness, cost, cutting time and surface damage, a proper selection guidance for regular user has been provided.

Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of Ti-6Al-4V Using Zinc Coated Brass Wire

2014 ◽  
Vol 592-594 ◽  
pp. 416-420 ◽  
Author(s):  
Singaravelu D. Lenin ◽  
A. Uthirapathi ◽  
Ramana Reddy P.S. Venkata ◽  
Muthukannan Durai Selvam
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Brass Wire

The present paper describes the influence of pulse-on-time on performance features such as Metal Removal Rate (MRR), Kerf width, Surface Roughness (SR) on cutting Titanium alloy (Ti-6Al-4V) in wire electrical discharge machining (WEDM) using zinc coated brass wire. The deionised water is used as dielectric fluid. The process parameters such as wire tension, wire speed, flushing pressure, discharge current, sparking voltage and pulse off time have kept constant at appropriate values throughout the experiment and the pulse on time is varied at nine different intervals. It was found that pulse-on-time is the most significant factor which greatly influences MRR, kerf width, and SR. It was also observed that taper at the end of cutting zone which is unavoidable occurrence for the machined part. This is due to the erosion of wire material. The surface roughness increases with increase in pulse on time also with higher rate of MRR.

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