Study of Micro Structural Material Changes after WEDM Based on TEM Lamella Analysis

Mouralová, Kateřina; Zahradníček, Radim; Beneš, Libor; Prokeš, Tomáš; Hrdý, Radim; Fries, Jiří

doi:10.3390/met10070949

Cited by 14 publications

(11 citation statements)

References 18 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…During the cutting process, a clamping nerve is maintained in the area (Figure 12). The WEDM surfaces offer a different appearance than the milled surface, with craters instead of cutting tool marks [6], which are produced by the electrical discharges. This gives the parts a matte color that is quite different from the bright appearance of the milled parts.…”

Section: Mark Of the Clamp (Flat Area)mentioning

confidence: 99%

“…A dielectric fluid such as water allows isolating the wire from the workpiece to achieve a high current density, it cools the heated surface of the wire and it removes the material particles. Due to the high temperatures reached, the surface layer melts and then it quickly cools because of the fluid, leading to the so-called recast layer [6]. Heat can also induce tensile residual stresses, cracks, or microporosity on the parts' surface [7,8].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

View full text Add to dashboard Cite

Cam-follower mechanisms are usually employed in different machines, like combustion engines, sewing machines, machine tools, etc. In the present paper, the option to manufacture cams utilizing wire electrical discharge machining (WEDM) has been considered. For this, surface roughness and shape error of cam profiles manufactured by the processes of milling and wire electrical discharge machining (WEDM) are presented. The methodology used covers different stages: design, prototyping, manufacturing, and measurement of the cams. As a reference, a cam-follower mechanism from a motorcycle internal combustion engine has been used. A reverse engineering process has been performed to determine the geometrical parameters of the mechanism, which are used for the synthesis of the profile of the cam and its subsequent design. The manufacturing process of the cams has been assisted by CAD-CAM (Computer Assisted Drawing-Computer Assisted Manufacturing) software. Using fused filament fabrication (FFF), a physical prototype of the cam has been manufactured, in order to validate the goodness of the design. Finally, the roughness and shape parameters have been measured on the contour surface of the cams. The arithmetical mean roughness Ra value of the milled cam was 0.269 μm, below the requirement of 0.4 μm, and shape error was 18 μm, below 50 μm. Shape error of the WEDM cam of 48 μm meets the requirements for cams. However, the Ra value of 1.212 μm, exceeded the limit. For this reason, a finish operation is recommended in this case. Some advantages of WEDM cams over milled cams are that different conductive materials can be employed, more complex shapes can be obtained, and that, in rough operations, the amount of material to be removed in subsequent operations is considerably reduced.

show abstract

Section: Mark Of the Clamp (Flat Area)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

View full text Add to dashboard Cite

show abstract

“…The sublimation point of the nanocomposite is determined by the most low-melting component; it is alumina with the temperature T of 2072 °C in the case of the chosen nanocomposite. Aluminum oxide 1 2.10 × 10 5 ÷ 10 6 Titanium carbide 1 6.0•10 3…”

Section: Materials and Discharge Gapmentioning

confidence: 99%

“…Electrical discharge machining is a well-known technology used for processing conductive materials [1][2][3][4], while there are always developed techniques to subject the non-conductive material to electroerosive wear [5][6][7][8]. However, these techniques do not show any outstanding results due to small volumetric performance and expensive assisting materials-nanoparticles of precious or rare materials, labor-intensive techniques of conductive layers applications, etc.…”

Section: Introductionmentioning

confidence: 99%

Electrical Discharge Machining of Oxide Nanocomposite: Nanomodification of Surface and Subsurface Layers

Grigoriev

Волосова

Okunkova

et al. 2020

JMMP

View full text Add to dashboard Cite

The work is devoted to the research of the changes that occur in the subsurface layer of the workpiece during electrical discharge machining of conductive nanocomposite based on alumina with the use of a brass tool. The nanocomposite of Al2O3 + 30% of TiC was electroerosively machined in a water and hydrocarbon oil. The process of electrical discharge machining is accompanied by oscillations that were registered by diagnostic means. The obtained surface of the samples was researched by the means of scanning electron microscopy and X-ray photoelectron spectroscopy. The observed surface and subsurface changes provide grounding for the conclusions on the nature of processes and reactions that occur between two electrodes and nanomodification of the obtained surfaces that can be an advantage for a series of applications.

show abstract

“…Given that surface roughness is a critical aspect of defining machining result, a considerable number of studies have been carried out with the aim of optimizing the WEDM parameters for the machining of different materials, such as the work of Kavimani et al [10] and Mouralova et al [11]. By judging the importance of machining parameters, they were able to improve the parameter settings.…”

Section: Introductionmentioning

confidence: 99%

Influence of AISI D2 Workpiece Roughness on Heat Partition and Plasma Channel Radius in the WEDM Process

Wang

Sánchez

Izquierdo

et al. 2020

Metals

View full text Add to dashboard Cite

As an important advanced machining process, in Wire Electrical Discharge Machining (WEDM) certain fundamental issues remain need to be studied in-depth, such as the effect of part surface roughness on heat transfer mechanisms. In the WEDM process, roughing cut wire goes into the workpiece to do the first shaping and in trim cut the wire sweeps on the outer surface to improve the surface roughness. In both of these two cases, the generation of sparks depends on the passing surface roughness. Therefore, with AISI D2 material and brass wire, this paper presents a study of the influence of part surface roughness on heat partition and the radius of the plasma channel in the WEDM process. Through extensive single discharge experiments, it is shown that the removal capacity per discharge can increase if the discharge occurs on a smoother surface. A Finite Element thermal model was then used for inverse fitting of the values of heat partition and radius of the plasma channel. These parameters completely define the characteristics of the heat conduction problem. The results indicate a strong correlation between an increase in heat partition ratio and a decrease in part surface roughness. The values of plasma channel radius show an increase in this value when discharging on rougher surfaces. It means that with the increasing of plasma channel radius, the heat source goes into the workpiece more dispersed. In the case of rougher surface, although the there is more area that affected by the heat source, finally the temperature of most area cannot reach to the melting point and it causes the smaller crater radius and volume, while the metal removal rate decreases. These results contribute towards a more complete understanding of the influence of surface roughness to the spark occurring.

show abstract

Study of Micro Structural Material Changes after WEDM Based on TEM Lamella Analysis

Cited by 14 publications

References 18 publications

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Electrical Discharge Machining of Oxide Nanocomposite: Nanomodification of Surface and Subsurface Layers

Influence of AISI D2 Workpiece Roughness on Heat Partition and Plasma Channel Radius in the WEDM Process

Contact Info

Product

Resources

About