Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

Mouralová, Kateřina; Beneš, Libor; Prokeš, Tomáš; Bednár, J; Zahradníček, Radim; Jankovych, Robert; Fries, Jiří; Vontor, Jakub

doi:10.3390/ma13040893

Cited by 7 publications

(11 citation statements)

References 23 publications

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“…Copper and zinc formations are almost exclusively formed with EDX measurement sites 1 and 2, while these formations have a significantly lighter colour than the surrounding morphology. A similar segregation of elements, but this time in the form of an element derived from the workpiece material, was observed when machining Ampcoloy copper alloy [33]. The smooth bottoms of the craters clearly visible in Fig.…”

Section: Morphology Of Machined Surfaces Analysis Of Chemical Composition and Subsurface Areasupporting

confidence: 65%

“…A similar segregation of elements, but this time in the form of an element derived from the workpiece material, was observed when machining Ampcoloy copper alloy. 36 The smooth bottoms of the craters clearly visible in Figure 6(b) have also been studied on some other materials such as martensitic stainless steel 35 or pure titanium, 34 these locations being covered by only a minimal amount of diffused elements. Only very small cracks up to 10 µm in length were studied on the surfaces of the samples, and very rarely.…”

Section: Morphology Of Machined Surfaces Analysis Of Chemical Composi...mentioning

confidence: 99%

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Machining of B1914 nickel-based superalloy using wire electrical discharge machining

Mouralová

Polzer

Beneš

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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The unconventional technology of wire electrical discharge machining is a key engineering technology, designed primarily for machining of conventionally difficult machine materials. One of them is nickel alloys, which are majorly used in the aerospace and energy industries. The subject of research in this study was specifically the B1914 nickel-based superalloy, which was subjected to many analyses leading to an overall optimization of its machining using wire electrical discharge machining. In order to determine the effect of machine parameters setup (pulse off time, gap voltage, discharge current, pulse on time and wire feed) on cutting speed, topography, morphology, surface and subsurface layer quality, an extensive Box–Behnken design experiment consisting of 46 rounds was carried out. The analyses of the condition of the surface and subsurface layers were performed, including their chemical composition and changes caused by wire electrical discharge machining. It was found out that the factors like pulse off time, discharge current and pulse on time have the greatest effect on the cutting speed, although from the point of view of surface topography the parameter pulse off time is not significant. The remaining two parameters cause the cutting speed to act against the surface topography i.e. with the increasing cutting speed, the surface topography gets worse and vice versa.

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Section: Morphology Of Machined Surfaces Analysis Of Chemical Composition and Subsurface Areasupporting

confidence: 65%

Section: Morphology Of Machined Surfaces Analysis Of Chemical Composi...mentioning

confidence: 99%

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

Mouralová

Polzer

Beneš

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…In point 1, this needle is composed of 91.3 wt.% lead, while similar needles were previously studied on this material in the Mouralova et al study. 33 Segregation of individual elements on the surface due to the effects of WEDM was also described when machining the composite material Al6061 in the Doreswamy et al study. 34 No defects in the form of cracks were evident on any of the machined samples, which is very good in terms of maintaining the predicted component life and proper functionality.…”

Section: Surface Morphology Analysismentioning

confidence: 85%

Analysis of the effect of material thickness during the WEDM processon cutting speed, topography and morphology

Mouralová

Beneš

Prokeš

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Wire electrical discharge machining (WEDM) is an unconventional machining technology that is indispensable in many industries. Machining is performed using the thermoelectric principle, while it is possible to machine all at least minimally electrically conductive materials. Due to the wide range of applications of WEDM, it is necessary to ensure the appropriate quality of machined surfaces, regardless of the thickness of the machined materials, while maintaining an acceptable cutting speed. For this purpose, this study was performed to analyse the effect of material thickness on the cutting speed, morphology and topography of Ampcoloy 35 material. In this study, thicknesses from 5 to 160 mm were analysed in 5 mm increments with the same machine parameter settings. The surface topography and morphology were studied using electron and light microscopy, and cross-sections of the sample were created to examine the condition of the subsurface layer. It was found that the values of Ra at the edge ranged from 1.8 to 3.2 µm and in the middle of the sample from 1.7 to 3 µm, while the trend of increasing Ra with thickness is not visible. It is clear from the morphology analysis that a rugged surface with more craters was created at the edges than in the middle of the sample, while segregated lead needles were also formed at the edges of the samples.

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“…This process is suitable for the machining of high-strength and high ductility alloys, as it does not cause any distortion during machining. However, this process is quite time-consuming as it has a very slow material removal rate and has high energy consumption [5,6]. Therefore, it would be quite useful to employ other types of processes in the production of molds and mold inserts, made from these copper-based alloys, especially copper-beryllium.…”

Section: Introductionmentioning

confidence: 99%

Wear Behavior of Uncoated and Coated Tools in Milling Operations of AMPCO (Cu-Be) Alloy

et al. 2021

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Copper-Beryllium alloys have excellent wear resistance and high mechanical properties, they also possess good electrical and thermal conductivity, making these alloys very popular in a wide variety of industries, such as aerospace, in the fabrication of tools for hazardous environments and to produce injection molds and mold inserts. However, there are some problems in the processing of these alloys, particularly when these are subject to machining processes, causing tools to deteriorate quite rapidly, due to material adhesion to the tool’s surface, caused by the material’s ductile nature. An assessment of tool-wear after machining Cu-Be alloy AMPCOLOY 83 using coated and uncoated tools was performed, offering a comparison of the machining performance and wear behavior of solid-carbide uncoated and DLC/CrN multilayered coated end-mills with the same geometry. Multiple machining tests were conducted, varying the values for feed and cutting length. In the initial tests, cutting force values were registered. The material’s surface roughness was also evaluated and the cutting tools’ edges were subsequently analyzed, identifying the main wear mechanisms and how these developed during machining. The coated tools exhibited a better performance for shorter cutting lengths, producing a lower degree of roughness on the surface on the machined material. The wear registered for these tools was less intense than that of uncoated tools, which suffered more adhesive and abrasive damage. However, it was observed that, for greater cutting lengths, the uncoated tool performed better in terms of surface roughness and sustained wear.

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Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

Cited by 7 publications

References 23 publications

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

Analysis of the effect of material thickness during the WEDM processon cutting speed, topography and morphology

Wear Behavior of Uncoated and Coated Tools in Milling Operations of AMPCO (Cu-Be) Alloy

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