Degradation of wire electrode during electrical discharge machining of metal matrix composites

Pramanik, Alokesh; Basak, A.K.

doi:10.1016/j.wear.2015.11.011

Cited by 41 publications

(25 citation statements)

References 28 publications

(31 reference statements)

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“…During WEDM process, wire material is also removed gradually in addition to workpiece material due to generation of high temperature. The wire electrode also experience significant deformation due to high temperature and tension, and in many instances the wire fails (physically brake down) during machining process [12,32]. Fig.…”

Section: Resultsmentioning

confidence: 99%

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Pramanik

Basak

Prakash

2019

Heliyon

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Non-conventional machining process for instance, wire electrical discharge machining (WEDM) of titanium alloys is gaining attention due to non-contact nature of this process. To deepen the understanding in this area, this study investigates surface generation, kerf width, discharge gap, material removal rate and wire degradation during WEDM of Ti6Al4V alloy. Pulse on time (4–10 μs), flushing pressure (7–18 MPa) and wire tension (800–1700 gf) were varied and resulting influences on output parameters were analysed. It was found that, machined surfaces consist of multi-layered recast layer with the presence of cracks, holes as well as traces of materials from electrode wire. The composition and roughness of the machined surface varies slightly with respect to machining condition without following any trend. In addition, deformation and morphology of deformed wire electrode after the WEDM process was also reported in this study.

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Section: Resultsmentioning

confidence: 99%

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Pramanik

Basak

Prakash

2019

Heliyon

Self Cite

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“…The time is taken to resume machining after each wire failure is non-productive as all subunits are running and consuming power until the operator rethreads the wire. (Pramanik & Basak, 2016) probed into the degradation of the wire electrode, by altering the pulse on time and wire tension to divulge the interaction between affecting parameters. In this study, it is explored that the electric sparks not only remove the workpiece material but also affect the dimensions of the electrode.…”

Section: Original Articlementioning

confidence: 99%

A Novel Approach to Improve WEDM Performance on Inconel718, by Using Small Diameter Zinc Coated Wire

R¹,

Tjprc²

2019

IJMPERD

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In this paper, a novel approach to increase the wire electrical discharge machining performance by using small diameter wire is presented. As wire in wire electrical discharge machining (WEDM) is the only externally added into the intrinsic system, its role is determinant in the performance of WEDM. It is characterised by essential mechanical, electrical, and thermal properties. Here 0.15, 0.20, and 0.25 mm diameter zinc coated wire is used, on 8, 10 and 12 mm thick rectangular blocks of Inconel718, to investigate the performance measures such as the material removal rate (MRR), and surface roughness (SR). Taguchi L27 orthogonal array is employed to ascertain the effect of varying diameter. It is observed that MRR and SR. are greatly influenced by wire diameter. A small size wire diameter is proved to be better on all accounts, promising a high MRR with lower SR. Further SEM studies revealed that the alterations such as debris and oxide deposition seen on the surface are very less and is acceptable with no foreign particle accumulation on the surface revealed by EDAX. There are no cracks developed in the cutting with small diameter wire.

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“…Amineh et al [46] improved the surface finish of WEDM surface by removing the recast layer through a magnetic abrasive finishing method. Authors studied the influence of WEDM process parameters on machining of Al-based composites, namely Al6063/SiCp composite [43], Aluminium metal matrix composite [35]; Boron carbide [81], and Aluminium (6351) alloy reinforced with 54 wt. % Silicon Carbide (SiC) and 0, 5, 10 wt.…”

Section: Effect Of Process Parametersmentioning

confidence: 99%

A progress review in wire electrical discharge machining process

Balan¹,

Giridharan²

2017

Int. J. Automot. Mech. Eng.

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Wire Electrical Discharge Machining (WEDM) is an electrothermal non-traditional machining process used for machining electrically conductive materials that are difficult to machine. Material removal in WEDM is by means of spark erosion. WEDM is proven to be the alternative for producing complex parts with higher degree of dimensional accuracy and better surface finish. Over the years, a significant amount of research was globally carried out to explore the WEDM process capability. This paper aims to explore the research work carried on parametric influence of WEDM process variables on various output performance measures. The paper also highlights various modelling techniques to predict optimal machining conditions and explore the feasibility of applying WEDM process to machine advanced materials. Combined technology that benefits from the virtues of WEDM and conventional method is also highlighted in this paper. The final section discusses the development and possible research trend in WEDM process.

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Degradation of wire electrode during electrical discharge machining of metal matrix composites

Cited by 41 publications

References 28 publications

Understanding the wire electrical discharge machining of Ti6Al4V alloy

Understanding the wire electrical discharge machining of Ti6Al4V alloy

A Novel Approach to Improve WEDM Performance on Inconel718, by Using Small Diameter Zinc Coated Wire

A progress review in wire electrical discharge machining process

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