Experimental study of the effects of wire EDM on the characteristics of ferritic steel, at a micro-scale on the contour cut surface

Abstract

This study, on a micro-scale, of the WEDM cut surfaces of specimens to which the contour method of residual stress measurement is being applied provides detailed information about the effects of the cutting process on the surface quality. This is defined by a combination of several parameters: variation in surface contour profile, sub-surface damage and surface texture. Measurements were taken at the start, the middle and at the end of the cut. This study shows that during WEDM cutting, a thin layer, extending to a depth of a few micrometres below the surface of the cut, is transformed. This layer is known as the recast layer. Using controlled-depth etching and X-ray diffraction, it is shown that this induces an additional tensile residual stress, parallel to the plane of the cut surface. The WEDM cut surface and sub-surface characteristics are also shown to vary along the length of the cut. Moreover, these micro-scale changes were compared with macro-scale residual stress results and provides an indication of the point at which the changes occurred by cutting process can be significantly relative to the macro-scale residual stress in a specimen.

Optimization of Process Parameters for Minimum Surface Roughness in Wire Electrical Discharge Machining of AISI 1045 Steel Using Taguchi Method

“…Slatineanu et al (4) aimed to reveal the aspects that characterize the process, phenomena, performances, and evolution trends specific to the wire electrical discharge machining processes, as they result from scientific works published mainly in the last two decades. Naveed (5) shows that during WEDM cutting, a thin layer extending to a depth of a few micrometers below the surface of the cut, is transformed. This layer is known as the recast layer.…”

Prognostics, Health Assessment, and Modelling of Material Removal Rate by EDM for Al 6061 and AISI 304 via Cockroach Swarm and Fruit Fly Optimization Approaches

“…e addition of EDM to the methods of machining has created an optimal process of manufacturing extremely complicated products that are independent or self-reliant of the properties of the material [3]. is is due to the integrity of the potential of EDM to cheaply produce products, which are hard and complicated to be done by the conventional machining processes.…”

Effect of Wire Electrical Discharge Machining on the Surface of Ebm-Additive Manufactured Niti Alloys

“…Studies shows that during micro-EDM machining, constituent elements of the tool material are deposited on the sub-surface and coat an antibacterial layer by controlling the process parameters including dielectric fluid, and pulse energy. On the other hand, the wire electrical discharge machining offers various post processing options, such as processing the holes, sample preparation for tensile and compression tests to obtain the final geometry of the workpiece [13,14]. The surface finish and dimensional accuracy of specimen are significantly vital for the engineering applications.…”