Sustainable production of high-uniformity workpiece surface quality in wire electrical discharge machining by fabricating surface microstructure on wire electrode

Yan, Hongjie; Kabongo, Djo Bakadiasa; Yan, Zhaojun; Han, Fenglin; Chen, Zhi

doi:10.1016/j.jclepro.2020.120881

Cited by 22 publications

(6 citation statements)

References 21 publications

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“…The use of standard for the exchange of product model data-numerical control is found to be beneficial for energy demand management in machining activities (Wang et al , 2019). Furthermore, a new way of welding surface microstructure on a wire electrode for sustainable production of high-uniformity work piece surface quality is found to be feasible (Yan et al , 2020).…”

Section: Literature Reviewmentioning

confidence: 99%

Relationships between industry 4.0, sustainable manufacturing and circular economy: proposal of a research framework

Bag

Pretorius

2020

IJOA

316

179

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Purpose The digital revolution has brought many challenges and opportunities for the manufacturing firms. The impact of Industry 4.0 technology adoption on sustainable manufacturing and circular economy has been under-researched. This paper aims to review the latest articles in the area of Industry 4.0, sustainable manufacturing and circular economy and further developed a research framework showing key paths. Design/methodology/approach Qualitative research is performed in two stages. In the first stage, a review of the extant literature is performed to identify the barriers, drivers, challenges and opportunities. In the second stage, a research framework is proposed to integrate Industry 4.0 technology (big data analytics powered artificial intelligence) adoption, sustainable manufacturing and circular economy capabilities. Findings This research extends the knowledge base by providing a detailed review of Industry 4.0, sustainable manufacturing, and circular economy and proposes a research framework by integrating these three contemporary concepts in the context of supply chain management. Through an exploration of this integrative research framework, the authors propose a future research agenda and seven research propositions. Research limitations/implications It is important to understand the interplay between institutional pressures, tangible resources and human skills for Industry 4.0 technology (big data analytics powered artificial intelligence) adoption. Industry 4.0 technology (big data analytics powered artificial intelligence) adoption can positively influence sustainable manufacturing and circular economy capabilities. Managers must also put more attention to sustainable manufacturing to develop circular economic capabilities. Social implications Factory workers and the local communities generally suffer from various adverse effects resulting from the traditional manufacturing process. The quality of the environment is deteriorating to such an extent that people even staying miles away from the factory are also affected due to environmental pollution that is generated from factory operations. Hence, sustainable manufacturing is the only choice left to manufacturers that can help in the transition to a circular economy. The research framework can help firms to enhance circular economy capabilities. Originality/value This review paper contains the most updated work on Industry 4.0, sustainable manufacturing and circular economy. It also proposes a research framework to integrate these three concepts.

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Section: Literature Reviewmentioning

confidence: 99%

Relationships between industry 4.0, sustainable manufacturing and circular economy: proposal of a research framework

Bag

Pretorius

2020

IJOA

316

179

View full text Add to dashboard Cite

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“…Based on the previously reported experiments and our experiment experience [39][40][41][42], the Taguchi experiment with 5 factors and 5 levels was designed. In addition, experiments were applied with ZCSMWE and BWE for comparison.…”

Section: Experiments Designmentioning

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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“…Yan et al [17] proposed a new method for preparing surface microstructures on wire electrodes, thereby realizing the sustainable production of a lowroughness average value and high-roughness uniformity of the workpiece surface. Ming et al [18] reported a comparative study between magnetic fieldassisted EDM and conventional EDM and found that the energy utilization efficiency increased by 15.2%, while the material removal rate increased by 21.9% under the effect of an external magnetic field.…”

Section: Introductionmentioning

confidence: 99%

Research on microstructure evolution and surface quality of WEDM for magnetic refrigerant rare-earth gadolinium

Sun,

Shi,

et al. 2024

Surf. Topogr.: Metrol. Prop.

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Rare-earth gadolinium (Gd) is preferable for manufacturing regenerators of the core components of room-temperature magnetic refrigeration owing to its unique magnetocaloric and mechanical properties. However, the surface quality of the regenerator plays a crucial role in the heat transfer effect and service life of magnetocaloric systems during wire electrical discharge machining (WEDM) when fabricating rare-earth Gd array microstructure regenerators. In this study, different process parameters were used to conduct a process experiment of the WEDM of rare-earth Gd. First, the evolution of the surface microstructure and its causes were analyzed using a single-factor experiment, while a corrosion test was conducted on the samples. The analysis showed that the pulse-on time and open voltage considerably affected the surface quality of the processed samples, while the samples with better surfaces exhibited good corrosion resistance. Additionally, a Taguchi experiment was designed, and a regression analysis used to establish regression models between the process parameters (pulse-on time, pulse-off time, peak current, open voltage, and water pressure) and both surface roughness (SR) and material removal rate (MRR). The results showed that the average prediction errors of SR and MRR were only 5.34 % and 5.48 %, respectively.

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Sustainable production of high-uniformity workpiece surface quality in wire electrical discharge machining by fabricating surface microstructure on wire electrode

Cited by 22 publications

References 21 publications

Relationships between industry 4.0, sustainable manufacturing and circular economy: proposal of a research framework

Relationships between industry 4.0, sustainable manufacturing and circular economy: proposal of a research framework

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

Research on microstructure evolution and surface quality of WEDM for magnetic refrigerant rare-earth gadolinium

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