Fabricating Micro-texture on Surface of Cutting Tool Based on NC WEDM Technology

Yang, Fengshuang; Pan, Chen; Shi, Yi

doi:10.1088/1755-1315/440/2/022084

Cited by 5 publications

(3 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Examples of mathematical equations have been built to define the input factors influencing the output responses kerf width and the surface roughness (Ra) [38]. An example of the higher-order mathematical model was recently proposed in [39]. In order to estimate output processes, such as SR and SW, Speeding et al [40] created modeling methodologies using response surface methodology and artificial intelligence technology within a different input level.…”

Section: Modeling and Optimizing The Wedm Processmentioning

confidence: 99%

Wire Electrical Discharge Machining Process: Challenges and Future Prospects

Shehata

El‐Hadad

Attia

2022

International Journal of Materials Technology and Innovation

View full text Add to dashboard Cite

Titanium alloys, due to their distinctive properties, are widely used in modern commercial applications. However, these alloys face challenges of machining via traditional techniques such as milling and turning. One of the unique thermal machining techniques that offer an effective choice with the highest dimensional precision and surface finish for Ti alloys is Wire Electrical Discharge Machining (WEDM). This method is based on the effect of erosion, where a highly repetitive electrical spark causes the material to be removed. The key challenges in WEDM are machining mode, wire electrode, dielectric, metal removal rate, and surface integrity as related to WEDM parameters were analyzed and correlated. Furthermore, Low metal removable rates, excessive tool wear, the production of recast layers, and heat-affected zones provide additional dilemmas when applied to titanium alloys. The majority of these obstacles occur as a result of titanium alloys' remarkable properties, such as low thermal conductivity, high melting temperature, and wear resistance. The first part of this paper highlights the research trends in WEDM on finding the relationships among various process parameters, such as cutting speed, the time between two pulses, servo voltage, peak current, dielectric fluid, wire tension, and machining modes that have a crucial impact on a variety of process responses, such as MRR, Ra, sparking gap, and WWR as well as surface integrity. The second part of the article also discusses various modeling, simulation, and optimization technique for monitoring process parameters to investigate the feasibility of various control practices for achieving the optimum machining conditions. The final part of the paper highlights these advancements and includes a roadmap for the potential future directions of WEDM research.

show abstract

Section: Modeling and Optimizing The Wedm Processmentioning

confidence: 99%

Wire Electrical Discharge Machining Process: Challenges and Future Prospects

Shehata

El‐Hadad

Attia

2022

International Journal of Materials Technology and Innovation

View full text Add to dashboard Cite

show abstract

“…Due to the small size of the micro-weave structure, which makes it more difficult to process, the currently known methods of micro-texturing preparation include EDM, laser processing, grinding, and plasma etching. Since laser machining uses laser beam energy to ablate the material, which has the characteristics of good controllability and fast machining speed, it has been widely used in the research of micro-woven tools [21][22][23]. Puoza J.C. et al [24] utilized a laser to fabricate micro-structures on the metal surface and found that micro-pitted structures with high quality, smooth surfaces, and less debris can be processed by using laser machining.…”

Section: Introductionmentioning

confidence: 99%

Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys

Zhang,

Shi,

Wang

et al. 2024

Lubricants

View full text Add to dashboard Cite

Titanium alloys are widely used in various fields, but milling titanium alloy materials often leads to problems such as high milling forces, increased milling temperatures, and chip adhesion. Thus, the machinability of titanium alloys faces challenges. To improve the milling performance of titanium alloy materials, this study analyzes the effective working area on the surface of the milling cutter through mathematical calculations. We design micro-grooves in this area to utilize their friction-reducing and wear-resisting properties to alleviate the aforementioned issues. The effective working area of the ball end milling cutter’s cutting edge is calculated based on the amount of milling and the installation position between the milling cutter and the workpiece. By observing the surface structure of seashells, micro-grooves are proposed and designed to be applied in the working area of the milling cutter surface. The impact of the micro-groove area on the milling cutter surface and spindle speed on milling performance is discussed based on milling simulation and experimental tests. Experimental results show that the cutting force, milling temperature, and chip resistance to adhesion produced by micro-groove milling cutters are superior to conventional milling cutters. Milling cutters with three micro-grooves perform best at different spindle speeds. This is because the presence of micro-grooves on the surface of the milling cutter improves the friction state, promoting a reduction in milling force, while the micro-grooves also serve as storage containers for chips, alleviating the phenomenon of chip softening and adhesion to the cutter. When conducting cutting tests with a milling cutter that has three micro-grooves, the milling force is reduced by 10% to 30%, the milling temperature drops by 10% to 20%, and the surface roughness decreases by 8% to 12%.

show abstract

“…At present, the main processing methods for surface texturing include micro-electrical discharge machining [6], laser processing technology [7], electrochemical machining [8], and precision mechanical machining [9,10]. However, when it comes to practical industrial applications, a large number of textures need to be processed.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Microcolumn Arrays Using Through-Mask Electrochemical Micromachining on the 42CrMo Alloy Steel

Zhou

Liu

Chen

et al. 2023

AMR

View full text Add to dashboard Cite

Studies have shown that surface texture can improve lubrication state and reduce friction and wear. The cold pressing process of micro-units can prepare surface textures at low cost, in large quantities, and with high efficiency, but the micro-pillar array mold required for the cold pressing process is difficult to prepare. In this study, the influence of mask electrochemical processing parameters on the height and height uniformity of the micropillar array was studied by orthogonal experiment on the 42CrMo alloy steel. Four main factors are designed in the orthogonal experiment, namely voltage, duty cycle, frequency, and mask spacing, and each factor is set to three levels. The results of the range analysis show that: voltage and duty cycle are positively correlated with the height of the microcolumn, but negatively correlated with uniformity, and when the duty cycle is 50%, the uniformity of the microcolumn decreases sharply; The height and uniformity of the microcolumns increase with the increase of mask spacing. The height of the microcolumn is positively correlated with the frequency, and the uniformity of the microcolumn first increases and then decreases with the increase of frequency. Therefore, in order to meet the height and uniformity requirements at the same time, the grey correlation analysis method was used to obtain the optimal processing parameters: 35 V (voltage), 30% (duty cycle), 300 um (spacing), and 5 kHz (frequency). The average height of the microcolumns prepared by this parameter is 57.632 um and the microcolumn has excellent high uniformity.

show abstract

Fabricating Micro-texture on Surface of Cutting Tool Based on NC WEDM Technology

Cited by 5 publications

References 23 publications

Wire Electrical Discharge Machining Process: Challenges and Future Prospects

Wire Electrical Discharge Machining Process: Challenges and Future Prospects

Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys

Fabrication of Microcolumn Arrays Using Through-Mask Electrochemical Micromachining on the 42CrMo Alloy Steel

Contact Info

Product

Resources

About