Recast Layer Formation during Wire Electrical Discharge Machining of Titanium (Ti-Al6-V4) Alloy

Pramanik, Alokesh; Basak, A.K.; Prakash, Chander; Shankar, S.; Sharma, Shubham; Narendranath, S.

doi:10.1007/s11665-021-06116-1

Cited by 35 publications

(20 citation statements)

References 53 publications

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“…The other reason could be that more metal erosion and melting occurs in the machining zone due to the high production of spark energy due to electro- is provided by increasing pulse on time and peak current. Thermoelectric behavior removes more material with increased discharge energy and duration [22][23][24][25][26]. The removed debris particle would stick between the workpiece and electrode, which causes the additional load to the already machined surface.…”

Section: Machining Of Composites At Initial and Optimal Conditionsmentioning

confidence: 99%

“…The same is indicated as the reason for an increase in the overcut. A discrete electric pulse amplifies a severe intensification in peak current and pulse on time, resulting in the formation of a degraded surface [26][27][28]. The secondary sparking energy frequently occurs during machining at this moment, and as a result, the overcut is increased.…”

Section: Machining Of Composites At Initial and Optimal Conditionsmentioning

confidence: 99%

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Al-Mg-MoS2 Reinforced Metal Matrix Composites: Machinability Characteristics

et al. 2022

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Several components are made from Al-Mg-based composites. MoS2 is used to increase the composite’s machinability. Different weight percent (3, 4, and 5) of MoS2 are added as reinforcement to explore the machinability properties of Al-Mg-reinforced composites. The wire cut electrical discharge machining (WEDM) process is used to study the machinability characteristics of the fabricated Al-Mg-MoS2 composite. The machined surface’s roughness and overcut under different process conditions are discussed. The evaluation-based distance from average solution (EDAS) method is used to identify the optimal setting to get the desired surface roughness and overcut. The following WEDM process parameters are taken to determine the impact of peak current, pulse on time, and gap voltage on surface roughness, and overcut. The WEDM tests were carried out on three different reinforced samples to determine the impact of reinforcement on surface roughness and overcut. The surface roughness and overcut increase as the reinforcement level increases, but the optimal parameters for all three composites are the same. According to EDAS analysis, I3, Ton2, and V1 are the best conditions. Furthermore, peak current and pulse on-time significantly influence surface roughness and overcut.

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Section: Machining Of Composites At Initial and Optimal Conditionsmentioning

confidence: 99%

Section: Machining Of Composites At Initial and Optimal Conditionsmentioning

confidence: 99%

Al-Mg-MoS2 Reinforced Metal Matrix Composites: Machinability Characteristics

et al. 2022

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“…In WEDM as the dielectric fluid is not able to reach the machining region, the cooling rate of the machining surface is lower than that of outer surface due to which the melted material gets re-solidified quickly on the machined surface with an absence of grain boundaries leading to the formation of a thin layer of re-solidified melted debris termed as 'recast layer'. Pramanik et al 102 reported that the recast layer has visible cracks at regular intervals with no evidence of a grain boundary. They further observed that the HAZ appears just beneath the recast layer, with grain boundaries plainly visible without cracks.…”

Section: Analysis Of Recast Layer Formationmentioning

confidence: 99%

A comprehensive review on wire EDM performance evaluation

Alam

Siddiquee

Khan

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Wire electric discharge machining (WEDM) technique is a fast-growing, advanced manufacturing process which is used for machining of hard materials including various alloys of steel, nickel, tungsten, cubic boron nitride, metal matrix composites (MMC's), superalloys, and ceramic materials. Moreover, it is employed for machining complex profiles and micromachining of hardened materials which are not feasible by various conventional machining processes. Generally, this process is employed to machine electrically conductive materials but during this scenario, it is also being used for machining of electrically low conducting and non-conducting ceramics including silicon carbide, aluminium oxide, silicon nitrate, and zirconium oxide ceramics by modifying the WEDM method with assisted electrode technique or forming composite of conductive and non-conductive materials. This paper presents a comprehensive review on the influence of several WEDM control factors including pulse-on time, pulse-off time, wire feed rate, peak current, wire tension, type of wire (tool) materials, types of base materials and types of powder mixed dielectric fluids on the output responses such as surface roughness (Ra), material removal rate (MRR), width of cut (kerf), wire wear ratio (WWR), wire breakage, microstructural defects, recast layer thickness, and thermal deformation. Moreover, various simulation methods, post processing methods and optimization of WEDM parameters using various techniques were discussed and at last this paper shapes the important recommendations and upcoming developments in WEDM.

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“…In WEDM, if the discharge debris is not ejected by the flowing dielectric in time, a part of the material etched by a high temperature will stay in the discharge gap and be cooled down by the flowing dielectric, becoming balls and reattaching on the surface of the workpiece [45,46]. At the same time, a part of the debris will be adsorbed on the surface, hence forming the recast layer [47][48][49][50][51]. In addition, the cracks on the machining surface by ZCSMWE are both shorter and narrower, while the cracks on the machining surface by BWE are longer and wider.…”

Section: Workpiece Surface Topographymentioning

confidence: 99%

A New Wire Electrode for Improving the Machining Characteristics of High-Volume Fraction SiCp/Al Composite in WEDM

Chen

Zhou

et al. 2022

Materials

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In wire electrical discharge machining, due to the random distribution of the insulating SiC particles, frequent wire rupture, low machining efficiency and surface quality when the common brass wire electrode (BWE) is used to process high-volume content SiCp/Al composite often appears. To address this issue, this paper proposes a new preparation method of zinc coating and surface microstructure on wire electrodes (ZCSMWE). The preparation process of ZCSMWE includes casting, coating, annealing and plastic processing. The experimental results show that, compared with BWE, ZCSMWE can increase material removal rate (MRR) by 16.67%, reduce surface roughness (Ra) by 21.18% and reduce wire rupture under the same discharge parameters. The analysis of workpiece surface topography shows that ZCSMWE can significantly decrease the recast layer and microcrack on the machined surface. The improvement mechanism of ZCSMWE main includes: The low work function zinc can promote the forming of the discharge channel. The vaporization of low boiling temperature zinc can reduce the temperature of the discharge gap and promote the ejecting of workpiece material. In addition, the surface microstructure on ZCSMWE can make the discharge spark more uniformly distributed and increase the proportion of the effective discharge, which contributes to making the discharge crater on the workpiece and wire electrode shallower and more uniform. The surface microstructure on ZCSMWE can also effectively improve the dielectric circulation, which can promote discharge debris to be expelled out and reduce the temperature in the discharge gap. Then, the wire rupture and microcracks on the workpiece surface can be reduced.

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Recast Layer Formation during Wire Electrical Discharge Machining of Titanium (Ti-Al6-V4) Alloy

Cited by 35 publications

References 53 publications

Al-Mg-MoS2 Reinforced Metal Matrix Composites: Machinability Characteristics

Al-Mg-MoS2 Reinforced Metal Matrix Composites: Machinability Characteristics

A comprehensive review on wire EDM performance evaluation

A New Wire Electrode for Improving the Machining Characteristics of High-Volume Fraction SiCp/Al Composite in WEDM

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