Analysis of selected effects of the conventional and unconventional machining of titanium alloys

In this article, the results of wire WEDM (wire electrical discharge machining) of Ti6Al4V are collated by turning with modified wiper tool geometry. The electrode is CuZn37 brass wire with a diameter of 0.25 mm The analysis of 3D geometry of the Ti6Al4V alloy surface after wiper and WEDM cutting is presented. The possibilities and limitations of wiper and WEDM machining of titanium alloys were indicated.

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

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.592-594.416 ◽

2014 ◽

Vol 592-594 ◽

pp. 416-420 ◽

Cited By ~ 3

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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Study of Micro Structural Material Changes after WEDM Based on TEM Lamella Analysis

Metals ◽

10.3390/met10070949 ◽

2020 ◽

Vol 10 (7) ◽

pp. 949 ◽

Cited By ~ 4

Author(s):

Katerina Mouralova ◽

Radim Zahradnicek ◽

Libor Benes ◽

Tomas Prokes ◽

Radim Hrdy ◽

...

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Subsurface Layer ◽

Base Material ◽

Wire Electrical Discharge Machining ◽

Transmission Electron ◽

Machined Parts ◽

Tem Lamella ◽

Unconventional Machining

Wire electrical discharge machining is an unconventional machining technology that is crucial in many industries. The surface quality of the machined parts is carefully monitored, but the condition of the subsurface layer also plays a crucial role, especially in case of defects occurrence such as cracks or burnt cavities. The subsurface layer of individual materials is affected differently due to wire electrical discharge machining. For this reason, this study was carried out focusing on a detailed analysis of transmission electron microscope (TEM) lamella made of Ti-6Al-4V titanium alloy, AlZn6Mg2Cu aluminum alloy, pure molybdenum, Creusabro 4800 steel, and Hardox 400 steel. The attention was first of all paid to the concentration and distribution of individual elements in the recast layer and also in the base material, which was often affected by wire electrical discharge machining. Further, a diffraction analysis was performed for each TEM lamella in the adhesive area and in the base material area. In order to assess the macro-effects on the machined material, the topography analysis of the machined surfaces and the morphology analysis were performed using electron microscopy.

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Effect of Wire Electrode Materials on Performance Characteristics for Wire Electrical Discharge Machining of Metal Matrix Composite Material

Volume 2A: Advanced Manufacturing ◽

10.1115/imece2020-23511 ◽

2020 ◽

Author(s):

Gurupavan Hurugalavadi Ramu ◽

Holalu Venkatadas Ravindra ◽

Devegowda Tadagavadi Muddegowda

Keyword(s):

Silicon Carbide ◽

Composite Materials ◽

Surface Finish ◽

Metal Matrix ◽

Electrical Discharge ◽

Electrode Materials ◽

Electrical Discharge Machining ◽

Electrode Wear ◽

Wire Electrical Discharge Machining ◽

Brass Wire

Abstract Composite materials are the advanced materials which are widely used in manufacturing industries. The most commonly used composite materials are metal matrix composites. Due to the presence of abrasive reinforcing particles, traditional machining of these causes severe tool wear and hence reduces the life of cutting tool. Wire electrical discharge machining (WEDM) is quite successful for machining of metal matrix composites. Wire Electrical Discharge machining is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. One of the main research fields in WEDM is related to the improvement of the process productivity by avoiding wire breakage. Wire electrodes used in WEDM are the core of the system. In this study the effect of different wire electrode materials on electrode wear and surface finish for wire electrical discharge machining of metal matrix composite material were investigated. The experiments were conducted under the following process parameters viz., pulse-on time, pulse-off time, wire feed speed and current. For the experiment the aluminium 6061 alloy with 0%, 5%, and 10% of silicon carbide (SiC) reinforcement material was used. To conduct the experiment CNC wire EDM machine with two different wires viz., molybdenum and brass wire was used. Experimental results indicate that for better surface finish of Al6061 alloy, the brass wire is more suitable. The use of brass wire as electrode material leads to significant reduction in electrode wear in machining of Al-5%SiC and Al-10%SiC composite materials compare to molybdenum wire. Increasing percentage of silicon carbide in aluminium 6061 alloy increases the variation in surface finish and electrode wear. Wire wear rate of both brass and molybdenum wire is increased with increase in percentage of silicon carbide.

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Experimental model on the wire wear for WEDM of hard to machine materials

Journal of Machine Engineering ◽

10.5604/01.3001.0013.6234 ◽

2019 ◽

Vol 19 (4) ◽

pp. 110-121

Author(s):

Dariusz POROS ◽

Stanislaw ZABORSKI ◽

Magdalena WISNIEWSKA

Keyword(s):

Thermal Conductivity ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Wire Electrical Discharge Machining ◽

Discharge Time ◽

The Wire ◽

Titanium Alloy Ti6al4v ◽

Semi Empirical ◽

Wire Wear ◽

Brass Wire

In this study, the wear of wire electrodes was investigated experimentally in wire electrical discharge machining. Naked brass wire, 0.25mm diameter, zinc oxide coated brass wire and brass CuZn20 coated with brass CuZn50 wire were applied in the conducted research. The wire wear ratio of WEDM of titanium alloy Ti6Al4V and cemented carbide B40 was described. As important WEDM parameters, the following variables were chosen: discharge time ton, average working voltage U. The following properties of machined materials, such as: melting point Tt, electrical conductivity σ, thermal conductivity K, thermal expansion coefficient k, density ρ, heat capacity cp, were also selected to develop the semi – empirical model of the wear of wire electrodes. The variation of the wire wear with cutting different materials by applying three different wire electrodes and process parameters was modelled semi – empirically by employing dimensional analysis.

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Fabrication of superhydrophobic NiTi shape memory alloy surface with inclined microstructure by wire electrical discharge machining

10.1109/3m-nano49087.2021.9599800 ◽

2021 ◽

Author(s):

Yonggang Hou ◽

Jinkai Xu ◽

Zhongxu Lian ◽

Shen Yang ◽

Changtai Zhai ◽

...

Keyword(s):

Shape Memory Alloy ◽

Shape Memory ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Alloy Surface ◽

Niti Shape Memory Alloy ◽

Wire Electrical Discharge Machining

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Effect of cryogenic treated brass wire electrode on material removal rate in wire electrical discharge machining

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406212438804 ◽

2012 ◽

Vol 226 (11) ◽

pp. 2750-2758 ◽

Cited By ~ 22

Author(s):

Jatinder Kapoor ◽

Sehijpal Singh ◽

Jaimal Singh Khamba

Keyword(s):

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Cryogenic Treatment ◽

Wire Electrical Discharge Machining ◽

Wire Electrode ◽

Deep Cryogenic Treatment ◽

Brass Wire

In this article, the effect of cryogenic treatment on the brass wire electrode used in wire electrical discharge machining is investigated. Deep cryogenic (−184°C) treatment is given to the brass wire electrode. The microstructure and crystalline phase of deep and non-cryogenic treated brass wire electrodes is observed by scanning electron microscope and X-Ray diffraction. The experimental results show that the structure is more refined in deep cryogenic treatment as compared to non-cryogenic treatment. The electrical conductivity of deep electrode is greatly improved. The effect of deep cryogenic treatment on the brass wire electrode is also investigated for the performance of wire electrical discharge machining. Taguchi experimental design has been applied to investigate the optimal parameters for maximum material removal rate. The ANOVA analysis indicates that type of wire, pulse width, time between two pulses and wire tension are significant factors for maximization of material removal rate. The cryogenic treatment results in improved material removal rate.

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