Prediction of the heat-affected zone of tool steel EN X37CrMoV5-1 after die-sinking electrical discharge machining

2016 ◽  
Vol 232 (8) ◽  
pp. 1395-1406 ◽  
Author(s):  
L’uboslav Straka ◽  
Slavomíra Hašová
Keyword(s):  
Mathematical Models ◽  
Heat Affected Zone ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Advanced Technology ◽  
Technological Parameters ◽  
Machined Surface ◽  
Knowledge Database ◽  
Subsurface Layers

This article describes the results of the experimental research on the heat-affected zone of the subsurface layers of eroded surface on medium-alloyed samples of steel EN X37CrMoV5-1 (W.-Nr. 1.2343) which occurs in die-sinking electrical discharge machining with Cu electrode. It assesses the direct effect and consequences of the heat-affected zone on the final quality of the machined surface. The aim of the experiments was to contribute to the knowledge database defining the influence of the main technological parameters of electrical discharge machining on the microhardness changes and the total depth of the heat-affected zone of the subsurface layers of experimental samples. The results of the experimental measurement were transformed into the mathematical models allowing simulation and prediction of the final quality of the machined surface after die-sinking electrical discharge machining tool steels with Cu electrode. The purpose of the mathematical models is to determine the optimal combination of process parameters and thereby achieve the desired quality of the products produced by this advanced technology.

scholarly journals Influence of MTP on Surface Roughness and Geometric Accuracy of Machined Surface at WEDM

2020 ◽  
Vol 5 (2) ◽  
pp. 91-97
Author(s):  
Luboslav Straka ◽  
Gabriel Dittrich
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Geometric Accuracy ◽  
Technological Parameters ◽  
Machined Surface ◽  
Number Of Factors ◽  
Progressive Technology ◽  
Quality Of Products ◽  
The Impact

Electrical discharge machining technology is one of the most precise machining methods. Therefore, even the smallest deviation of micro and macro geometry generally has a significant impact on the overall quality of products produced by this progressive technology. The quality of the machined surface after Wire Electrical Discharge Machining (WEDM) is influenced by a large number of factors, most of which are influenced by the Main Technological Parameters (MTP). The aim of the paper was to describe the results of experimental research aimed at assessing the impact of MTP for WEDM on the quality of machined surface in terms of geometric accuracy and roughness parameters Ra and Rz. The samples were made of high alloyed ledeburitic chromium-molybdenum-vanadium steel designated EN X155CrVMo12-1 on a Sodick AQ535 electroerosion machine. The tool used was a standard compact brass wire  0.25 mm with the designation Elecut Brass CuZn37.

scholarly journals 302 Evaluation of Machined Surface Quality of Long Fiber FRM by Electrical Discharge Machining

2000 ◽  
Vol 2000.53 (0) ◽  
pp. 49-50
Author(s):  
Rikio HIKIJI ◽  
Yoshihiro KAWANO ◽  
Koji ABURADA ◽  
Masakazu HARADA ◽  
Minoru ARAI
Keyword(s):  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machined Surface ◽  
Machined Surface Quality

Recast layer and heat-affected zone structure of ultra-fined grained low-carbon steel machined by electrical discharge machining

2019 ◽  
Vol 234 (5) ◽  
pp. 933-944 ◽  
Author(s):  
Mohammad Sajjad Mahdieh
Keyword(s):  
Heat Affected Zone ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Recast Layer ◽  
Machining Process ◽  
Coarse Grain ◽  
Hardness Profile ◽  
Low Carbon ◽  
Machined Surface ◽  
Microstructural Changes

Ultra-fined grain materials are thermodynamically unstable and when they are exposed to a high external thermomechanical energy, such as electrical discharge machining process, many microstructural changes will occur in them. However, in the electrical discharge machining process, the recast layer and heat affected zone are the undesired and inevitable consequences of this process, which have several adverse effects on the surface layers of the workpiece including microstructural changes, grain growth, alternation of hardness, initiation of micro-cracks and changing the composition. All of which deteriorate the surface integrity. In this article, the effects of the electrical discharge machining process on the ultra-fined grain steel samples have been studied through investigating the microstructure of the recast layer and heat affected zone via scanning electron microscopy, optical microscopy and X-ray diffraction technique. The thickness of the recast layer and heat affected zone as well as the cracks’ density and the hardness profile of the ultra-fined grain samples was measured and the results were compared with coarse grain samples. Results show that the undesired effects of electrical discharge machining process on the ultra-fined grain samples are more considerable than the coarse grain ones; for instance, by comparison with coarse grain samples, relatively thicker recast layer and heat affected zone are formed in the ultra-fined grain samples, in which the microstructure changed more considerably. In addition, on one hand, the more extended cracks on the electrical discharge machined surface of the ultra-fined grain samples were observed, and on other hand, the hardness profile of the ultra-fined grain samples varies more noticeably from the surface to the depth.

Influence of Process Parameters on Geometric Precision of Machined Surface after WEDM

2017 ◽  
Vol 756 ◽  
pp. 107-118
Author(s):  
Ľuboslav Straka ◽  
Slavomíra Hašová
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Negative Impact ◽  
Geometric Accuracy ◽  
Machined Surface ◽  
Influence Of Process Parameters ◽  
Geometric Precision ◽  
Geometric Size ◽  
Nominal Surface

Geometrical precision machined surface is generally understood as mainly precision shape, orientation, location and run-out. As a rule, it is measuring the appropriate deviations from the nominal surface. The geometric size of this deviation from the nominal surface can in practice affect the conventionally measured value for the dimension and the dimension whilst maintaining the required tolerance. Because the WEDM technology is among the most accurate technology, the small final geometric accuracy deviation has also a negative impact on the final quality of the machined surface. The paper aimed to describe errors geometrical precision of machined surface which occurs in wire electrical discharge machining (WEDM) and quantify their scope.

Ti-6Al-4V Surfaces in SiC Powder Mixed Electrical Discharge Machining

2013 ◽  
Vol 856 ◽  
pp. 226-230 ◽  
Author(s):  
Hamidullah Yaşar ◽  
Bülent Ekmekci
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dielectric Liquid ◽  
Operational Parameters ◽  
Electrical Parameters ◽  
Machined Surface ◽  
Optical Scanning ◽  
Surface Topographies ◽  
Powder Suspension

The role of suspended particles on Ti-6Al-4V surface in Powder Mixed Electrical Discharge Machining (PMEDM) is studied using SiC powder mixing in water dielectric liquid. Surface modifications due to the additives in dielectric liquid are investigated by means of optical, scanning electron microscopy and energy dispersive spectroscopy. The attachment of added powders and surface topographies interrelated with powder suspension concentration, particle size and electrical parameters such as pulse on duration and current. The influence on discharge transitivity with respect to SiC additives is noticed with pock like features on the surface. The geometry and size of these features indicated a robust dependency with respect to operational parameters and indicated the role of secondary discharges during PMEDM. SiC particles severely transferred from di-electric liquid to machined surface at critical operational parameters and implied that the process could be also used as a surface alloying technique.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

scholarly journals Sub-Microstructure of Surface and Subsurface Layers after Electrical Discharge Machining Structural Materials in Water

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1040
Author(s):  
Sergey N. Grigoriev ◽  
Marina A. Volosova ◽  
Anna A. Okunkova ◽  
Sergey V. Fedorov ◽  
Khaled Hamdy ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Structural Materials ◽  
12Kh18n10t Steel ◽  
Mean Deviation ◽  
Water Medium ◽  
Tool Electrode ◽  
Marquardt Algorithm ◽  
Subsurface Layers ◽  
Electrical Wear

The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransformations occurred in surface and subsurface layers during electrical discharge machining two structural materials such as anti-corrosion X10CrNiTi18-10 (12kH18N10T) steel of austenite class and 2024 (D16) duralumin in a deionized water medium were researched. The machining was conducted using a brass tool of 0.25 mm in diameter. The measured discharge gap is 45–60 µm for X10CrNiTi18-10 (12kH18N10T) steel and 105–120 µm for 2024 (D16) duralumin. Surface roughness parameters are arithmetic mean deviation (Ra) of 4.61 µm, 10-point height (Rz) of 28.73 µm, maximum peak-to-valley height (Rtm) of 29.50 µm, mean spacing between peaks (Sm) of 18.0 µm for steel; Ra of 5.41 µm, Rz of 35.29 µm, Rtm of 43.17 µm, Sm of 30.0 µm for duralumin. The recast layer with adsorbed components of the wire tool electrode and carbides was observed up to the depth of 4–6 µm for steel and 2.5–4 µm for duralumin. The Levenberg–Marquardt algorithm was used to mathematically interpolate the dependence of the interelectrode gap on the electrical resistance of the material. The observed microstructures provide grounding on the nature of electrical wear and nanomodification of the obtained surfaces.

Study Regarding Process of the Electrical Discharge Machining with Magnetic Activation of the Welded Joints of some Materials High Alloy Steel

2021 ◽  
Vol 890 ◽  
pp. 141-146
Author(s):  
Mihail Aurel Țîțu ◽  
Dumitru Mnerie ◽  
Diana Cristina Dragomir ◽  
Gabriela Victoria Mnerie
Keyword(s):  
Alloy Steel ◽  
Welded Joints ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Scientific Paper ◽  
Electric Discharges ◽  
Technological Parameters ◽  
High Alloy ◽  
High Alloy Steel ◽  
Magnetic Activation

The scientific paper presents an extensive research on modeling and optimizing the technological parameters of the process for processing by processing electric discharges with massive electrode with and without magnetic activation. Scientific research is based on real data collected from the process of electrical discharges performed on various samples extracted from areas of welded joints of metal components made of high alloy steel. The processing of experimental data was performed both classically and actively, especially the method of the central factorial experiment composed of orthogonal and rotary. The process parameters that were initially modeled and subsequently optimized were based on a series of independent variables characteristic of dimensional processing by copying the shape of the electrical discharge processing. Subsequent research conclusions and directions, as well as original contributions, are an experimentally validated point of view and worthy of consideration. All these fundamental ideas highlighted above find their explanations and the corresponding explicit treatment in the content of this scientific paper that addresses both managers at all levels and researchers.

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