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1

The effect of selected wedm parameters on cut surface quality of 2017A aluminum

Jamróz Konrad, Gałda Lidia

Technologia i Automatyzacja Montażu

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2024

|

nr 1

3--9

EN

With the wire electrical discharge machining (WEDM), good quality machined surfaces can be achieved. The WEDM is worth considering for machining fasteners used in assembly processes. This paper presents a study of the WEDM cutting process of aluminum 2017A using an WEDM machine of the FR 400 type. After applying different cutting speeds, the characteristics of the cut surface were evaluated. Despite some differences in the shape of surface profiles and surface morphology noted after WEDM cutting at different speeds, the analysis of variance concluded that the WEDM cutting speed in the studied variation range of 23-125 μm/s has no significant effect on surface roughness. At the highest speed studied, machining efficiency can be increased, affecting cost and energy reduction, while maintaining an acceptable and comparable level of surface quality after WEDM cutting.

PL

Dzięki obróbce elektroerozyjnej można uzyskać dobrą jakość obrabianych powierzchni. Warto rozważyć zastosowanie obróbki elektroerozyjnej do obróbki elementów złącznych wykorzystywanych w procesach montażowych. W artykule przedstawiono badania procesu cięcia elektroerozyjnego aluminium 2017A z zastosowaniem elektrodrążarki typ FR 400. Po zastosowaniu zróżnicowanej prędkości obróbki poddano ocenie stan powierzchni cięcia. Pomimo zauważonych pewnych różnic w kształcie profili powierzchni i morfologii powierzchni po cięciu elektroerozyjnym z różnymi prędkościami, to w wyniku analizy wariancji stwierdzono, że prędkość cięcia poprzez elektrodrążenie w badanym zakresie zmienności 23-125 μm/s nie wywiera istotnego wpływu na chropowatość powierzchni. Przy największej badanej prędkości można zwiększyć wydajność obróbki, wpływając na zmniejszenie kosztów i energii, zachowując akceptowalny i porównywalny poziom jakości powierzchni po cięciu elektroerozyjnym.

2

Optimizing the Surface Parameters of Titanium (Ti-6Al-4V) Alloy Specimens Using WEDM Process Based on Taguchi-DEAR Algorithm

Thangaraj Muthuramalingam, Moiduddin Khaja, Annamalai Ramamurthy, Mian Syed Hammad, Almutairi Zeyad, Machnik Ryszard

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no. 6

422--431

EN

Because of its excellent mechanical qualities and weldability, titanium alloy is used in many different biomedical applications. Wire electrical discharge machining may be used to machine materials with such greater strengths and intricate forms. Using Taguchi-Data Envelopment Analysis-based Ranking (DEAR) approach and zinc-diffused coated brass wire electrode to improve Titanium alloy machining was the goal of this research project. The quality metrics that were taken into consideration were sur-face roughness, kerf width, and material removal rate. Among the selected factors, with an error of 2.7%, the optimal configuration of input factors was determined to be 130 µs (Ton), 40 µs (Toff), 50 V (SV), 6 A (IP), and 8 Kg (WT). Due to its relevance in the process of deionization, the Ton is the high-est influential parameter for creating quality measurements.

3

Struna diamentowa Maleńkie narzędzie o wielkich możliwościach

Wiśniewska Magdalena

Stal, Metale & Nowe Technologie

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2023

|

nr 9-10

24--29

PL

Narzędzie strunowe powstało do przecinania na skalę masową monokryształów krzemu. Czy jednak potencjał struny diamentowej nie jest znacznie większy? Dowiedz się, jakie są możliwości oraz zastosowania w obszarach wykraczających poza przecinanie kryształów technicznych.

4

Środowiskowe aspekty obróbki elektroerozyjnej

Tadeusz Leppert

Obróbka Metalu

|

2023

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nr 4

34--43

PL

Obróbka elektroerozyjna (Electro-Discharge Machining . EDM) jest jednym z najbardziej rozpowszechnionych sposobów niekonwencjonalnego kształtowania przedmiotów, stosowanym do obróbki powierzchni o złożonych kształtach, zwłaszcza materiałów o dużej twardości i trudno skrawalnych. Z tego powodu zrozumiałe jest dążenie do zwiększania efektywności tej obróbki. Z drugiej strony, rosnące zainteresowanie wpływem ogółu procesów produkcyjnych na środowisko naturalne i zdrowie pracowników, spowodowało zintensyfikowanie badań zmierzających do opracowania nowych lub zmodyfikowanych sposobów obróbki EDM zmniejszających lub eliminujących ich negatywne oddziaływania środowiskowe. W artykule przedstawiono analizę czynników procesu drążenia elektroerozyjnego będących źródłem zagrożeń środowiskowych. Scharakteryzowano także podejmowane próby ich ograniczenia z zastosowaniem innowacyjnych rozwiązań technologicznych obróbki elektroerozyjnej.

EN

Electro-Discharge Machining (EDM) is one of the most common methods of unconventional forming of objects, used for surface treatment of complex shapes, especially materials with high hardness and difficult to machine. For this reason, it is understandable to seek to increase the efficiency of this treatment. On the other hand, the growing interest in the environmental and health impacts of production processes in general has led to an intensification of research into new or modified EDM treatments to reduce or eliminate their negative environmental impacts. In this paper there were presented an analysis of the EDM factors generating environmental risks and characterizes the attempts to limit their negative influence by introducing innovative EDM technologies.

5

Effect of different wire materials on WEDM performance of Bio-compatible material

Pandey Gaurav Kumar, Patel Praveen Bhai, Kumar Abhishek, Niranjan Ramendra Singh, Katiyar Vikas, Chandra A. K

Production Engineering Archives

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2022

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Vol. 28, Iss. 1

50--55

EN

The present experimental investigation aims to analyse the effect of various machining parameters, such as pulse peak current (Ion), pulse on time (Ton), pulse off time (Toff) and spark voltage (SV) on the surface roughness (SR) and material removal rate(MRR) by using continuous traveling of both wire electrode (i.e. brass wire and zinc-coated brass wire). The present work also analyses the effect of types of wires, such as brass wire and zinc-coated brass wire used during machining of Titanium alloy (Ti-6Al-4V) on Surface roughness (SR) and material removal rate (MRR). This work studies the correlation between various response parameter such SR and MRR by using same machining parameter by for both wires.

6

An experimental investigation of wire breakage and performance optimisation of WEDM process on machining of recycled aluminium alloy metal matrix composite

Kannan P. R., Periasamy K., Pravin P., Vinod Kumaar J. R.

Materials Science Poland

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2022

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Vol. 40, No. 3

12--26

EN

In this research, a novel aluminium metal matrix composite (AMMC) was developed using recycled aluminium alloy as a matrix with 5% alumina as reinforcement. The machining experiments were conducted by varying the input parameters such as voltage (Vs), wire feed rate (Fw), current (Ip), pulse on time (ONT) and pulse off time (OFFT), on wire breakage. The effect of voltage level and wire breakage frequency was analysed. The parameter combinations for machining the slot of size 5 mm width and 10 mm height with high machining rate (MR) and less surface roughness (Ra) were analysed using the Criteria Importance Through Intercriteria Correlation (CRITIC) and simple additive weighting (SAW) methods. The wire breakage frequency is lesser at minimum peak current. The optimal parameter combination for higher MR and lower Ra is found to be at 30 V, 7 mm/min, 30 A, 120 μs (ONT) and 70 μs (OFFT). Analysis of variance (ANOVA) is performed to understand the significant factors affecting the WEDM process. ANOVA results predict that wire feed rate and voltage contribute 47.82% and 21.23%, respectively, to MR; and pulse on time shows a 23.06% influence on surface roughness. Scanning electron microscopy (SEM) was used to ascertain the pattern of wire breakage in WEDM, and based on the results obtained from employing this technique, it is inferred that the erosion and breakage of the wire are not instantaneous and that a cone shape is formed on the either portion of the wire.

7

Surface Topography of Inconel 718 Alloy in Finishing WEDM

Buk Jarosław

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no. 1

47--61

EN

The properties of Iconel 718 determine its application for parts operating in extremely tough conditions. The difficulties when machining nickel-based superalloys allowed in recent years for researching other machining methods. One of the proposed methods is Wire Electrical Discharge Machining (WEDM). It becomes possible to minimize or eliminate such problems associated with electrical discharge machining as microcracks, forming of a white layer, or high surface roughness. One way to avoid these issues is to apply finishing machining. The literature indicates that the peak current is the main parameter responsible for shaping the machined surface in finishing WEDM. Furthermore, few works focus on the electrode’s infeed, in particular there are not many papers regarding the influence of the infeed on the machined surface parameters. Therefore, the paper aims to investigate on the influence of the peak current and infeed during finishing WEDM on the surface properties of Inconel 718. The paper presents measurements of selected surface topography parameters and Abbot Firestone curves (AFC). The presented plots allowed to determine the ranges of the process parameters for which the lowest surface roughness values were achieved. Cross-sections were performed to measure the thickness of a white layer. Nanohardness HV0,01 measured by Berkovich tip was recorded to determine the size of a heat affected zone (HAZ). The correlation between the peak current Ic and the infeed z regarding the machined surface quality was presented.

8

Dynamic control of discharge energy during wedm for the purpose of eliminating vibrations of the wire tool electrode

Straka Ľuboslav, Kuchta Patrik

Management Systems in Production Engineering

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2021

|

nr 4 (29)

260--265

EN

Production in all industry fields is currently affected by new scientific and technical knowledge and the requirements for its rapid deployment. In many cases, the most modern and highly sophisticated technical systems are applied. Simultaneously, fully automated production systems are rather successfully used and progressive production technologies are implemented. In most cases, there is an integral part of a management system that operates the challenging technological processes. These processes would not be executable without the system's precise control, which provides a suitable precondition for ensuring the high quality of manufactured products. However, the customer's demanding requirements are not always met. These involve increased requests for the quality of the final product due to the reduction of the tolerance band and application of high-strength materials. This paper aims to describe one of the solutions by which it is possible to achieve a higher quality of the machined surface after wire electrical discharge machining (WEDM). The solution proposes that through dynamic management, the WEDM process eliminates the vibrations of the wire tool electrode and thereby achieves a substantial increase in the quality of the eroded area in terms of its geometric accuracy. With the support of an extensive database of information with precise exchange of information, the proposed system will allow to control the electro discharge process with regard to the optimal way of operation of the electro discharge machine on the basis of individually selected conditions.

9

Intelligent Machining of Shape Memory Alloys

Gupta Kapil

Advances in Science and Technology. Research Journal

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2021

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Vol. 15, no. 3

43--53

EN

Shape memory alloys are important biomaterials but difficult-to-machine (DTM). Their machining needs to be done using intelligent techniques to obtain a better machinability. Hybrid optimization is one of such techniques which can do modelling and optimization of machining parameters for the best values of machinability indicators. Wire electric discharge machining (WEDM) of shape memory alloy has been found as a prominent alternate to the conventional machining techniques, however it needs the assistance of intelligent techniques to machine such materials to get the optimum values of machinability indicators. In this paper, WEDM of shape memory alloy Ni55.8Ti is reported. WEDM has been done by varying four process parameters i.e. servo voltage SV, pulse-on time Pon, pulse-off time Poff, and wire feed rate WF using Taguchi L16 robust design of experiment technique. A hybrid optimization technique TOPSIS-Fuzzy-PSO has been successfully used to optimize these parameters (SV-50V; Pon-1µs; Poff-17 µs; WF-4 m/min) for the best possible values of material removal rate (MRR)- 0.049 g/min, maximum roughness- 11.45 µm, and recast layer- 22.10 µm simultaneously.

10

Comparative Analysis of Different WEDM Strategies Applied to Cut WC-Co Cemented Carbides

Poroś Dariusz

Advances in Science and Technology. Research Journal

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2021

|

Vol. 15, no. 4

126--135

EN

Cemented carbides WC-Co feature high mechanical properties and outstanding wear resistance. Traditional grinding of such hard workpiece features low material removal rate and diminished tool life. Notwithstanding that, even if, proper cooling fluid is applied; abrasive machining of cemented carbides characterizes poor efficiency. The aim of this study was to investigate the issue of WEDM of the cemented carbides WC-Co with two alternative materials of the wire electrodes applied. The presented experimental surface layer geometry measurements was carried out on a modern profilometer MITUTOYO SV 3200. Especially, WEDM results with wire flushing and in immersion were compared. Investigated were the effects of such input parameters as the pulse width and the time between two pulses on the output parameters such as area cutting efficiency, workpiece surface roughness in 2D and 3D. Analysing SEM microphotographs the surface layer defects after WEDM, cobalt depletion and pitting was discoursed. The analysed results provided WEDM of WC-Co cemented carbides with molybdenum wire electrode as seventy one percent less efficient and higher roughness was obtained for the same number of passes. The lowest height of the roughness on the surface after cutting with molybdenum wire amounted to Ra and Sa = 3.5 μm. Such roughness involves a 25 μm deep undesirable heat affected zone. WEDM with equal number of passes and brass wire resulted in roughness Ra and Sa =0,9 μm. In further research, an endeavour should be directed to examine different water and hydrocarbons derivative dielectrics impact on the surface layer structure and chemical composition of the machined WC-Co carbides.

11

Wpływ przygotowania powierzchni koła zębatego na wartość naprężeń własnych określanych metodą dyfrakcji rentgenowskiej

Fularski Robert, Ochał Kamil, Filip Ryszard

Zeszyty Naukowe Politechniki Rzeszowskiej. Mechanika

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2020

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z. 92 [300]

53--64

PL

Koła zębate przekładni lotniczych cechuje wysoki współczynnik niezawodności, wymagany ze względu na obszar zastosowania, dynamiczny charakter pracy oraz przenoszoną moc. Podczas całego cyklu eksploatacyjnego powierzchnie boczne zębów oraz obszary ich podstaw są narażone na uszkodzenia związane z różnymi stanami naprężeń występującymi w czasie zazębienia oraz okresie, kiedy poszczególne zęby kół współpracujących nie stykają się ze sobą. Koncentracja tych naprężeń, związana m.in. z dokładnością wykonania zębów, może prowadzić do różnego typu defektów, takich jak: „pitting”, zgniot, złom, uszkodzenia interferencyjne, wytarcia, wydarcia, odpryski, zatarcia czy przegrzania. W związku z tym koła zębate są poddawane m.in. badaniom naprężeń własnych metodą dyfrakcji rentgenowskiej, dla której procedura wykonania pomiarów oraz przygotowania materiału badawczego jest problematyczna ze względu na ograniczony lub niemożliwy bezpośredni dostęp do wymaganych obszarów pomiarowych. W niniejszym artykule opisano dwie metody przygotowania próbek do badań naprężeń własnych z zastosowaniem dyfraktometru rentgenowskiego wyposażonego w lampę chromową. Zakresem badań objęto: polerowanie elektrolityczne oraz cięcie elektroerozyjne. Przygotowane próbki kół zębatych, reprezentujące rozważane metody, poddano serii pomiarów na stanowisku badawczym, a otrzymane wartości naprężeń, reprezentujące ich stany w warstwie wierzchniej, poddano analizie. Porównano wpływ obydwu metod przygotowania kół zębatych na wartość naprężeń własnych warstwy wierzchniej zębów koła zębatego oraz wykazano, że rodzaj obróbki stosowanej podczas przygotowania próbek ma wpływ na wartości pomiarów naprężeń własnych.

12

Comparative analysis of WEDM with different wire electrodes applied to cut titanium Ti6Al4V

Poros Dariusz, Wisniewska Magdalena, Zaborski Stanislaw

Journal of Machine Engineering

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2020

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Vol. 20, No. 4

116--125

EN

The machining of titanium alloys by traditional methods causes many disadvantages of both technical and economic nature. These materials are characterized by very low thermal conductivity and belong to hard to machine materials. When machining these materials with conventional methods, there is a problem of chips thermal softening and increased tool wear. During machining, e.g. milling despite intensive cooling, the performance achieved is low. Although traditional processes of titanium alloys treatment pose many problems, the use of this strong and lightweight materials is still evolving. The aim of this article was to present the issue of wire electrical discharge machining of Titanium alloy Ti6Al4V. In particular, the comparison of brass wire and non-consumable molybdenum electrode and flushing techniques were analyzed. The relationship between the overheating of the machined surface layer and the magnitude of stresses and the formation of micro cracks on the machined surface was discussed. Based on its own research and the presented analysis of the literature on the subject, future directions of further research were indicated. An attempt should be made to investigate how flushing efficiency affects the machined shape, structural changes and chemical composition of the titanium alloy’s surface layer.

13

Heat affected zone analysis of Ti6Al4V after WEDM

Poroś Dariusz, Zaborski Stanisław, Karolczak Paweł

Mechanik

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2019

|

R. 92, nr 12

833--835

EN

Perspectives of applications WEDM for cutting titanium alloys are presented. There is space to explore how application of proper time parameters and the material of wire electrode for WEDM of titanium alloys affects the surface roughness, structure, the stress and the chemical composition of the formed surface layer.

PL

Przedstawiono problematykę obróbki elektroerozyjnej tytanu z uwzględnieniem doboru parametrów czasowych oraz materiału elektrody drutowej. Podjęto także temat analizy geometrii obrobionej powierzchni i strefy wpływu ciepła.

14

Analysis of selected effects of the conventional and unconventional machining of titanium alloys

Karolczak Paweł, Poroś Dariusz, Kowalski Maciej

Mechanik

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2019

|

R. 92, nr 10

655--657

EN

In this article, the results of wire WEDM (wire electrical discharge machining) of Ti6Al4V are collated by turning with modified wiper tool geometry. The electrode is CuZn37 brass wire with a diameter of 0.25 mm The analysis of 3D geometry of the Ti6Al4V alloy surface after wiper and WEDM cutting is presented. The possibilities and limitations of wiper and WEDM machining of titanium alloys were indicated

PL

W artykule zestawiono wyniki obróbki Ti6Al4V poprzez toczenie płytką o zmodyfikowanej geometrii typu wiper z wynikami obróbki WEDM (wire electrical discharge machining) za pomocą elektrody mosiężnej CuZn37 o średnicy 0,25 mm. Przenalizowano geometrię 3D powierzchni stopu Ti6Al4V po obróbce płytkami wiper oraz po obróbce elektroerozyjnej. Wskazano na możliwości i ograniczenia obróbki płytkami wiper oraz WEDM stopów tytanu.

15

Experimental model on the wire wear for WEDM of hard to machine materials

Poros Dariusz, Zaborski Stanislaw, Wisniewska Magdalena

Journal of Machine Engineering

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2019

|

Vol. 19, No. 4

110--121

EN

In this study, the wear of wire electrodes was investigated experimentally in wire electrical discharge machining. Naked brass wire, 0.25 mm diameter, zinc oxide coated brass wire and brass CuZn20 coated with brass CuZn50 wire were applied in the conducted research. The wire wear ratio of WEDM of titanium alloy Ti6Al4V and cemented carbide B40 was described. As important WEDM parameters, the following variables were chosen: discharge time ton, average working voltage U. The following properties of machined materials, such as: melting point Tt, electrical conductivity σ, thermal conductivity K, thermal expansion coefficient k, density ρ, heat capacity cp, were also selected to develop the semi-empirical model of the wear of wire electrodes. The variation of the wire wear with cutting different materials by applying three different wire electrodes and process parameters was modelled semi-empirically by employing dimensional analysis.

16

Investigation of the Influence of Process Parameters on Shape Deviation after Wire Electrical Discharge Machining

Świercz R., Oniszczuk-Świercz D., Zawora J., Marczak M.

Archives of Metallurgy and Materials

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2019

|

Vol. 64, iss. 4

1457--1462

EN

New materials require the use of advanced technology in manufacturing parts of complex shape. One of the modern non-conventional technology of manufacturing difficult to cut materials is the wire electrical discharge machining (WEDM). The article presents the results of theoretical and experimental research in the influence of the WEDM conditions and parameters on the shape deviation during a rough cut. A numerical model of the dielectric flow in the gap (ANSYS) was developed. The influence of the dielectric velocity field in the gap on the debris evacuation and stability of WEDM process was discussed. Furthermore, response surface methodology (RSM) was used to build empirical models for influence of the wire speed Vd, wire tension force Fn, the volume flow rate of the dielectric Qv on the flatness deviation after the WEDM.

17

Use of machine learning algorithm for the better prediction of SR peculiarities of WEDM of Nimonic-90 superalloy

Singh Nain S., Sai R., Sihag P., Vambol S., Vambol V.

Archives of Materials Science and Engineering

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2019

|

Vol. 95, nr 1

12--19

EN

Purpose: With the end goal to fulfil stringent structural shape of the component in aeronautics industry, machining of Nimonic-90 super alloy turns out to be exceptionally troublesome and costly by customary procedures, for example, milling, grinding, turning, etc. For that reason, the manufacture and design engineer worked on contactless machining process like EDM and WEDM. Based on previous studies, it has been observed that rare research work has been published pertaining to the use of machine learning in manufacturing. Therefore the current research work proposed the use of SVM, GP and ANN methods to evaluate the WEDM of Nimonic-90. Design/methodology/approach: The experiments have been performed on the WEDM considering five process variables. The Taguchi L 18 mixed type array is used to formulate the experimental plan. The surface roughness is checked by using surface contact profilometre. The evolutionary algorithms like SVM, GP and ANN approaches have been used to evaluate the SR of WEDM of Nimonic-90 super alloy. Findings: The entire models present the significant results for the better prediction of SR peculiarities of WEDM of Nimonic-90 superalloy. The GP PUK kernel model is dominating the entire model. Research limitations/implications: The investigation was carried for the Nimonic-90 super alloy is selected as a work material. Practical implications: The results of this study provide an opportunity to conduct contactless processing superalloy Nimonic-90. At the same time, this contactless process is much cheaper, faster and more accurate. Originality/value: An experimental work has been reported on the WEDM of Udimet-L605 and use of advance machine learning algorithm and optimization approaches like SVM, and GRA is recommended. A study on WEDM of Inconel 625 has been explored and optimized the process using Taguchi coupled with grey relational approach. The applicability of some evolutionary algorithm like random forest, M5P, and SVM also tested to evaluate the WEDM of Udimet-L605.The fuzzy- inference and BP-ANN approached is used to evaluate the WEDM process. The multi-objective optimization using ratio analysis approach has been utilized to evaluate the WEDM of high carbon & chromium steel. But this current research work proposed the use of SVM, GP and ANN methods to evaluate the WEDM of Nimonic-90.

18

Wpływ dosuwu elektrody w wykończeniowej obróbce WEDM na parametry jakościowe zamka wirnika

Burek J., Babiarz R., Płodzień M., Buk J.

Mechanik

|

2018

|

R. 91, nr 10

915--917

PL

Przedstawiono wpływ dosuwu elektrody w wykończeniowej obróbce WEDM (wire electrical discharge machining) zamków tarczy wirnika, wykonanego ze stopu Inconel 718, na dokładność kształtu oraz chropowatość powierzchni.

EN

The article presents the effect of electrode infeed in finishing machining of disk fir tree slots made of Inconel 718 alloy on shape accuracy and surface roughness in WEDM (wire electrical discharge machining).

19

Influence of the cut direction through the semi-finished product on the occurrence of cracks for X210Cr12 steel using WEDM

Mouralova K., Klakurkova L., Matousek R., Prokes T., Hrdy R., Kana V.

Archives of Civil and Mechanical Engineering

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2018

|

Vol. 18, no. 4

1318--1331

EN

Wire electrical discharge machining (WEDM) is a key technological process for the production of parts from semi-finished products to the final heat treatment as it also enables the machining of very hard material. The quality of an electro-erosive machined surface is a very important factor with regard to the consequent functionality and life cycle of the manufactured part. The occurrence of cracks or burned cavities is therefore an acceptable defect of the sub-surface area, which along with residual stress may lead to the destruction of the machining. This study deals with the influence of the cut direction through a semi-finished product on the occurrence of defects (cracks, burned cavities) regarding the influence of setting up the parameters of the machine (gap voltage, pulse on and off time, wire feed and discharge current) and the type of heat treatment of the material. In order to study the surface and sub-surface area of the machined samples, electron microscopy was used, including the use of the local EDX chemical analysis.

20

On Micromachining with a Focus on Miniature Gears by Non Conventional Processes. A Status Report

Chaudhary T., Siddiquee A. N., Chanda A. K., Khan Z. A.

Archive of Mechanical Engineering

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2018

|

Vol. LXV, nr 1

129--169

EN

Recent developments in automation and technology have revolutionized the way products are made. It is directly seen in the evolution of part miniaturization in the sectors such as aerospace, electronics, biomedicine and medical implants. Micromachining is a promising technology to fulfill the need of miniaturization. A review has been done on the micromachining processes such as micro electric discharge machining (micro-EDM) and wire EDM (WEDM), micro electrochemical machining (micro-ECM). Recent literature were studied and categorized in terms of materials, process parameters, performances, product manufactured, and miniature product generation. Starting with brief introduction to micromachining, classifications and applications, technical aspects of discussions from the literature have been presented on key factors such as parameters and the response variables. Important aspects of recast layer, heat effected zone, micro-hardness, micro cracks, residual stress, etc., have been given. A special focus is given to the status of the research on microgear manufacturing. Comparison has been made between other conventional process suitable for micro-gear manufacturing and WEDM. The miniature gear machined by WEDM shows the defect-free microstructure, better surface finish, thin recast layer and improved gear quality parameters such as profile and pitch. Finally, the research gaps and future research directions have been presented.