Display of WEDM Quality Indicators of Heat-Resistant Alloy Processing in Acoustic Emission Parameters

Abstract

The widespread nature of heat-resistant alloys is associated with the difficulties in their mechanical machining. It forces the use of the wire electrical discharge machining to be wider. The productivity, roughness, and dimensions of the modified layer of the machined surfaces are indicators of the machining quality. The search for new diagnostic parameters that can expand the information content of the operational monitoring/diagnostics of wire electrical discharge machining and accompany the currently used electrical parameters’ data is an urgent research task. The article presents the studies of the relationship between the parameters of acoustic emission signals accompanying wire electrical discharge machining of heat-resistant alloys, process quality indicators, and characteristics of discharge pulses. The results are presented as mathematical expressions and graphs demonstrating the experimentally obtained dependencies. The research focuses on the formed white layer during wire electrical discharge machining. Pictures of thin cross-sections of the machined surfaces with traces of the modified layer are provided. The issues of crack formation in the modified layer and base materials are considered.

Simulation and Optimization of Surface Roughness and Process Performance during Machining of HSS by Micro-WEDM Technology

“…The low performance of the electrical discharge process lies in the physical nature of the material removal method and, at the same time, in the current approach and method of controlling the electrical discharges that take place between the tool electrode and the processed material. One of the suitable approaches for solving the given problem can be the search for a unique combination of levels of input factors that can in all circumstances have a favorable impact on important output quality indicators of the machined surface while maintaining high performance of the electrical discharge process [ 22 , 23 , 24 , 25 ]. The roughness of the machined surface is coupled with its texture and integrity, and at the same time defines the final geometry of the workpiece.…”

Prediction and Multiparametric Optimization of the Machined Surface Quality of Tool Steels in Precise Wire Electrical Discharge Machining

“…Process parameters represent the mechanical and physical properties of the machined material, the properties of the wire electrode, the tension of the wire electrode, the diameter of the wire, the properties of the dielectric liquid, and other factors of the machining process that significantly affect the quality of the machined surface and the productivity of the electroerosion process. A suitable combination of the settings of the main technological and process parameters of the electroerosion process is sought with regard to finding the optimal values of the output indicators MRR and SR [7][8][9][10].…”