Electrical discharge machining of difficult to cut materials

• Autorzy: Świercz R. , Oniszczuk-Świercz D. , Dąbrowski L.

Identyfikatory

DOI

10.24425/ame.2018.125437

• Języki publikacji: EN

Abstrakty

EN

The development of industry is determined by the use of modern materials in the production of parts and equipment. In recent years, there has been a significant increase in the use of nickel-based superalloys in the aerospace, energy and space industries. Due to their properties, these alloys belong to the group of materials hard-to-machine with conventional methods. One of the non-conventional manufacturing technologies that allow the machining of geometrically complex parts from nickel-based superalloys is electrical discharge machining. The article presents the results of experimental investigations of the impact of EDM parameters on the surfaces roughness and the material removal rate. Based on the results of empirical research, mathematical models of the EDM process were developed, which allow for the selection of the most favourable processing parameters for the expected values of the surface roughness Sa and the material removal rate.

Słowa kluczowe

EN

EDM; Inconel 718; surface roughness; material removal rate; response surface methodology (RSM)

PL

EDM; Inconel 718; chropowatość powierzchni; szybkość usuwania materiału; metodologia powierzchni odpowiedzi (RSM)

• Wydawca: Komitet Budowy Maszyn PAN
• Czasopismo: Archive of Mechanical Engineering
• Rocznik: 2018
• Tom: Vol. LXV, nr 4
• Strony: 461--476
• Opis fizyczny: Bibliogr. 36 poz., rys., tab.

Twórcy

autor

Świercz R.

• Warsaw University of Technology, Institute of Manufacturing Technology, Warsaw, Poland

autor

Oniszczuk-Świercz D.

• Warsaw University of Technology, Institute of Manufacturing Technology, Warsaw, Poland

autor

Dąbrowski L.

• Warsaw University of Technology, Institute of Manufacturing Technology, Warsaw, Poland

Bibliografia

• [1] C.P. Mohanty, S.S. Mahapatra, and M.R. Singh. An experimental investigation of machinability of Inconel 718 in electrical discharge machining. Procedia Materials Science, 6:605–611, 2014. doi: 10.1016/j.mspro.2014.07.075.
• [2] S. Skoczypiec. Discussion of ultrashort voltage pulses electrochemical micromachining: a review. The International Journal of Advanced Manufacturing Technology, 87(1-4):177–187, 2016. doi: 10.1007/s00170-016-8392-z.
• [3] A. Ruszaj, J. Gawlik, and S. Skoczypiec. Electrochemical machining – special equipment and applications in aircraft industry. Management and Production Engineering Review, 7(2):34–41, 2016. doi: 10.1515/mper-2016-0015.
• [4] B.K. Sahu, S. Datta, and S.S. Mahapatra. On electro-discharge machining of Inconel 718 super alloys: an experimental investigation. Materials Today: Proceedings, 5(2):4861–4869, 2018. doi: 10.1016/j.matpr.2017.12.062.
• [5] L. Li, Z.Y. Li, X.T. Wei, and X. Cheng. Machining characteristics of Inconel 718 by sinking-DM and wire-EDM. Materials and Manufacturing Processes, 30(8):968–973, 2015 doi: 10.1080/10426914.2014.973579.
• [6] R. Świercz and D. Oniszczuk-Świercz. Influence of electrical discharge pulse energy on the surface integrity of tool steel 1.2713. Proceedings of the 26th International Conference on Metallurgy and Materials, pages 1450–1455, Brno, Czech Republic, 24–26 May 2017. WOS:000434346900234.
• [7] M. Kunieda, B. Lauwers, K.P. Rajurkar, and B.M. Schumacher. Advancing EDM through fundamental insight into the process. CIRP Annals – Manufacturing Technology, 54(2):64–87, 2005. doi: 10.1016/S0007-8506(07)60020-1.
• [8] B. Izquierdo, J.A. Sánchez, S. Plaza, I. Pombo, and N. Ortega. A numerical model of the EDM process considering the effect of multiple discharges. International Journal of Machine Tools and Manufacture, 49(3-4):220–229, 2009. doi: 10.1016/j.ijmachtools.2008.11.003.
• [9] B. Izquierdo, S. Plaza, J.A. Sánchez, I. Pombo, and N. Ortega. Numerical prediction of heat affected layer in the EDM of aeronautical alloys. Applied Surface Science, 259:780–790, 2012. doi: 10.1016/j.apsusc.2012.07.124.
• [10] G. Puthumana. An influence of parameters of micro-electrical discharge machining on wear of tool electrode. Archive of Mechanical Engineering, 64(2):149–163, 2017. doi: 10.1515/meceng-2017-0009.
• [11] A. Zyra, R. Bogucki, and S. Skoczypiec. Austenitic steel surface integrity after EDM in different dielectric liquids. Technical Transactions, 12:231–242, 2017. doi: 10.4467/2353737XCT.17.222.7765.
• [12] J. Holmberg, A. Wretland, J. Berglund, and T. Beno. Surface integrity after post processing of EDM processed Inconel 718 shaft. The International Journal of Advanced Manufacturing Technology, 95(5-8):2325–2337, 2018. doi: 10.1007/s00170-017-1342-6.
• [13] Z. Chen, J. Moverare, R.L. Peng, and S. Johansson. Surface integrity and fatigue performance of Inconel 718 in wire electrical discharge machining. Procedia CIRP, 45:307–310, 2016. doi: 10.1016/j.procir.2016.02.053.
• [14] C. Upadhyay, S. Datta, M. Masanta, and S.S. Mahapatra. An experimental investigation emphasizing surface characteristics of electro-discharge-machined Inconel 601. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 39(8):3051–3066, 2017. doi: 10.1007/s40430-016-0643-2.
• [15] D. Oniszczuk-Świercz and R. Świercz. Surface texture after wire electrical discharge machining. Proceedings of the 26th International Conference on Metallurgy and Materials, pages 1400–1406, Brno, Czech Republic, 24–26 May 2017. WOS:000434346900226.
• [16] L. Straka, I. Corný, J. Pitel’, and S. Hašová. Statistical approach to optimize the process parameters of HAZ of tool steel EN X32CrMoV12-28 after die-sinking EDM with SF-Cu electrode. Metals, 7(2):35, 2017. doi: 10.3390/met7020035.
• [17] P. Vishnu, N. Santhosh Kumar, and M. Manohar. Performance prediction of electric discharge machining of Inconel-718 using artificial neural network. Materials Today: Proceedings, 5(2):3770–3780, 2018. doi: 10.1016/j.matpr.2017.11.630.
• [18] V. Aggarwal, S.S. Khangura, and R.K. Garg. Parametric modeling and optimization for wire electrical discharge machining of Inconel 718 using response surface methodology. The International Journal of Advanced Manufacturing Technology, 79(1-4):31–47, 2015. doi: 10.1007/s00170-015-6797-8.
• [19] S. Prabhu and B.K. Vinayagam. Multiresponse optimization of EDM process with nanofluids using TOPSIS method and genetic algorithm. Archive of Mechanical Engineering, 63(1):45–71, 2016. doi: 10.1515/meceng-2016-0003.
• [20] Rahul, K. Abhishek, S. Datta, B.B. Biswal, and S.S. Mahapatra. Machining performance optimization for electro-discharge machining of Inconel 601, 625, 718 and 825: an integrated optimization route combining satisfaction function, fuzzy inference system and Taguchi approach. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 39(9):3499–3527, 2017. doi: 10.1007/s40430-016-0659-7.
• [21] M. Tanjilul, A. Ahmed, A.S. Kumar, and M. Rahman. A study on EDM debris particle size and flushing mechanism for efficient debris removal in EDM-drilling of Inconel 718. Journal of Materials Processing Technology, 255:263–274, 2018. doi: 10.1016/j.jmatprotec.2017.12.016.
• [22] A. Ahmed, A. Fardin, M. Tanjilul, Y.S. Wong, M. Rahman, and A.S. Kumar. A comparative study on the modelling of EDM and hybrid electrical discharge and arc machining considering latent heat and temperature-dependent properties of Inconel 718. The International Journal of Advanced Manufacturing Technology, 94(5-8):2729–2737, 2018. doi: 10.1007/s00170-017-1100-9.
• [23] S. Kumar, A.K. Dhingra, and S. Kumar. Parametric optimization of powder mixed electrical discharge machining for nickel-based superalloy inconel-800 using response surface ethodology. Mechanics of Advanced Materials and Modern Processes, 3:7, 2017. doi: 10.1186/s40759-017-0022-4.
• [24] G.S. Prihandana, T. Sriani, M. Mahardika, M. Hamdi, N. Miki, Y.S. Wong, and K. Mitsui. Application of powder suspended in dielectric fluid for fine finish micro-EDM of Inconel 718. The International Journal of Advanced Manufacturing Technology, 75(1-4):599–613, 2014. doi: 10.1007/s00170-014-6145-4.
• [25] G. Talla, S. Gangopadhyay, and C.K. Biswas. Effect of powder-suspended dielectric on the EDM characteristics of Inconel 625. Journal of Materials Engineering and Performance, 25(2):704–717, 2016. doi: 10.1007/s11665-015-1835-0.
• [26] A. Torres, I. Puertas, and C.J. Luis. EDM machinability and surface roughness analysis of INCONEL 600 using graphite electrodes. The International Journal of Advanced Manufacturing Technology, 84(9-12):2671–2688, 2016. doi: 10.1007/s00170-015-7880-x.
• [27] S. Spadło, P. Młynarczyk, and K. Łakomiec. Influence of the of electrical discharge alloying methods on the surface quality of carbon steel. The International Journal of Advanced Manufacturing Technology, 89(5-8):1529–1534, 2017. doi: 10.1007/s00170-016-9168-1.
• [28] S. Spadło, J. Kozak, and P. Młynarczyk. Mathematical modelling of the electrical discharge mechanical alloying process. Procedia CIRP, 6:422–426, 2013. doi: 10.1016/j.procir.2013.03.031.
• [29] I. Pliszka, N. Radek, and A. Gądek-Moszczak. Properties of WC-Cu electro spark coatings subjected to laser modification. Tribologia, 5:73–79, 2017.
• [30] T. Chmielewski, D. Golański, and W. Włosiński. Metallization of ceramic materials based on the kinetic energy of detonation waves. Bulletin of the Polish Academy of Sciences Technical Sciences, 63(2):449–456, 2015. doi: 10.1515/bpasts-2015-0051.
• [31] J. Holmberg, A. Wretland, and J. Berglund. Grit blasting for removal of recast layer from EDM process on Inconel 718 shaft: an evaluation of surface integrity. Journal of Materials Engineering and Performance, 25(12):5540–5550, 2016. doi: 10.1007/s11665-016-2406-8.
• [32] A. Ruszaj, S. Skoczypiec, and D. Wyszyński. Recent developments in abrasive hybrid manufacturing processes. Management and Production Engineering Review, 8(2):81–90, 2017. doi: 10.1515/mper-2017-0020.
• [33] T. Sałaciński, M. Winiarski, T. Chmielewski, and R. Świercz. Surface finishing using ceramic fiber brush tools. Proceedings of the 26th International Conference on Metallurgy and Material, pages 1220–1226, Brno, Czech Republic, 24–26 May 2017. WOS:000434346900195.
• [34] R. Świercz and D. Oniszczuk-Świercz. Experimental investigation of surface layer properties of high thermal conductivity tool steel after electrical discharge machining. Metals, 7(12):550, 2017. doi: 10.3390/met7120550.
• [35] Douglas C. Montgomery. Design and Analysis of Experiments. 9th edition. Wiley. 2017.
• [36] I. Ayesta, B. Izquierdo, J.A. Sánchez, J.M. Ramos, S. Plaza, I. Pombo, N. Ortega, H. Bravo, R. Fradejas, and I. Zamakona. Influence of EDM Parameters on slot machining in C1023 aeronautical alloy. Procedia CIRP, 6:129–134, 2013. doi: 10.1016/j.procir.2013.03.059.

Uwagi

EN

1. This work was supported by a grant from the Fundamental Research Funds of the Faculty of Production Engineering, Warsaw University of Technology. 2. Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2019).