Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

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

doi:10.3390/coatings10040406

Cited by 14 publications

(11 citation statements)

References 37 publications

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“…The nickel and zinc reaction at a temperature of 1000 • C has an explosive character and results in the formation of intermetallic ZnNi x (x = 0, 5, 10, 15, 20 wt%) [82][83][84][85][86]. It can be easily observed by the formation of non-periodic orange flashes in the discharge gap with the release of abundant black sediment during the processing of anti-corrosion austenite (nickel-containing) steels [25,34,[87][88][89]. Visually, the density of the flashes is less than the density of discharges and occurs with a lower frequency.…”

Section: Monitoring System and Tool Behaviormentioning

confidence: 99%

Wire Tool Electrode Behavior and Wear under Discharge Pulses

et al. 2020

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This work is devoted to researching the tool electrode behavior and wear under discharge pulses at electrical discharge machining. The experiments were conducted on the workpieces of 12Kh18N10T (AISI 321) chrome-nickel anti-corrosion steel and D16 (AA 2024) duralumin by a 0.25-mm-diameter CuZn35 brass tool in a deionized water medium. The developed diagnostic and monitoring mean based on acoustic emission registered the oscillations accompanying machining at 4–8 kHz. The obtained workpiece and non-profiled tool surfaces were investigated by optical and scanning electron microscopy. Calculated volumetric and mass removal rates showed the difference in the character of wear at roughing and finishing. It was shown that interaction between material components in anti-corrosion steel machining had an explosive character between Zn of brass and Ni of steel at a micron level and formed multiple craters of 30–100 µm. The secondary structure and topology of worn tool surfaces were caused by material sublimation, chemical interaction between material components at high heat (10,000 °C), explosive deposition of the secondary structure. Acoustic diagnostics adequately registered the character of interaction. The observed phenomena at the submicron level and microstructure of the obtained surfaces provide grounding on the nature of material interactions and electrical erosion wear fundamentals.

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Section: Monitoring System and Tool Behaviormentioning

confidence: 99%

Wire Tool Electrode Behavior and Wear under Discharge Pulses

et al. 2020

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“…The novelty of this study lies mainly in the use of the same material for the workpiece and for the tool, all in micro dimensions. This study builds on previous studies on EDM, such as the corner wear electrode study [5] or the study on defects occurrence while machining steels 1.2363 and 1.2343 ESR [6]. The results of this study can be used not only in the production of a key part for optical devices designed for testing car lights, but also for the production of other parts from thin films.…”

Section: Introductionmentioning

confidence: 87%

“…3.4. Multicriteria optimization As usual, there is a technical contradiction in EDM machining, which has been studied in several other publications, such as EDM machining of steels 1.2363 and 1.2343 ESR [6] or WEDM machining of Mg/CRT/BN composites [19], titanium alloy 6242 [20] or titanium (αβ) alloy [21]. Because if the Erosion rate is maximized, the Edge will be minimized, the Width will be targeted at 170 µm and the Length will be targeted at 5000 µm, the input parameter setting requirements will be conflicting, so multi-criteria optimization should be used.…”

Section: Number Of Sample Edge 1 (µM)mentioning

confidence: 99%

Micro-EDM Machining With Copper Foil

Mouralová

Bednár

Beneš

et al. 2021

Preprint

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Electrical discharge die-sinking machining (EDM) is one of the indispensable unconventional technologies enabling the machining of all materials that are at least minimally electrically conductive. Due to the clear trend of miniaturization of products, it is necessary to ensure their quality and accurate production, also with the help of micro-EDM. It is the optical instruments used for testing car lights that contain these miniaturized parts necessary for the correct functioning of the device. For this reason, this study was performed, which focused on the production of a precise slot measuring 5000x170 µm in a copper foil with a thickness of 125 µm. The same copper foil was used as a tool, which represents an advance in the production of micro-parts. A design of experiment Box and Behnken Response Surface Design was performed for a total of 15 rounds, monitoring the effect of machine setting parameters (Pulse current, Pulse on time and Voltage) on responses in the form of Erosion rate, corner radius, slot length and width. Using multi-criteria optimization, the optimal setting of the machine parameters for the production of a given slit was determined, which is Pulse current = 2.1 A, Pulse on time = 40 µs and Voltage = 238.8 V.

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“…It is thus clear that by using graphite electrodes it is possible to achieve a higher surface quality and thus lower values of the topography parameters. If we compare these values with the values using an older generator, which were analysed by the Mouralova study [5], we can see an improvement in the reduction of all values of individual parameters. 3D reliefs of the samples with the lowest surface topography values, which were Samples 3 and 50 each of a different material but both machined with a graphite electrode, are shown in Fig.…”

Section: Surface Topography and Statistical Evaluationmentioning

confidence: 93%

“…For this purpose, the following extensive study was carried out, which is unique not only in its scope, but also presents the latest knowledge gained using the new machine generator. This study builds on the knowledge gained during machining using an old generator presented in the Mouralova study [5]. As part of the design of experiment presented in this study, two steels 1.2363 and 1.2343ESR were machined, which were chosen due to their wide range of applicability, especially in the production of plastic injection moulds.…”

Section: Introductionmentioning

confidence: 99%

New EDM Generator Used for the Machining of 1.2363 and 1.2343ESR Steels

Mouralová

Bednár

Beneš

et al. 2021

Preprint

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The basic building block of any electric discharge machine is a generator, which ensures the operation of material separation itself. Not only the erosion rate and electricity consumption but also the quality of the machined surfaces depend on the design of the generator. These key factors for efficient machining have been investigated using a new energy-saving and powerful generator developed for the electric discharge machine (EDM) while machining 1.2363 and 1.2343ESR steels. In order to monitor and model the responses in the form of eroding rate and surface quality, a two-level half-factor experiment was performed with one replication at the corner points and two replications at the central points, for a total of 80 rounds. Both graphite and copper electrodes of sizes 10x10 mm and 100x100 mm were used for eroding and the influence of parameter settings: Open-voltage, Pulse current, Pulse on-time and Pulse off-time was monitored. It was found out that the shape of the electrode and Pulse current have the most significant effect on the erosion rate. The parameters Pulse current, Pulse on-time and their mutual interaction have the most significant effect on the surface topography. Statistically significant factors influencing the occurrence of defects turned out to be Pulse current, Pulse on-time and Material of workpiece, where it can be seen that the material 1.2343ESR is significantly less prone to the formation of surface defects.

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Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

Cited by 14 publications

References 37 publications

Wire Tool Electrode Behavior and Wear under Discharge Pulses

Wire Tool Electrode Behavior and Wear under Discharge Pulses

Micro-EDM Machining With Copper Foil

New EDM Generator Used for the Machining of 1.2363 and 1.2343ESR Steels

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