Experimental study on surface characteristics and improvement of microelectrode machined by low speed wire electrical discharge turning

Sun, Yangyang; Gong, Yadong; Liu, Yin; Li, Qiang; Zhou, Yunguang

doi:10.1016/j.acme.2017.02.004

Cited by 18 publications

(7 citation statements)

References 23 publications

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“…The characterization and formation mechanism of subsurface damage on Ni-based single-crystal superalloy microholes were analyzed by comparing the characteristics of Fig. 10, and the mean subsurface damage layer depth of micro-hole is 5.36 μm obtained by cylindrical microelectrodes with discharge energy of 3.2 × 10 −6 J, and the sub-surface damage depth is increased with the increase of discharge energy, which is consistent with [23]. Moreover, the effects of microelectrode structure and discharge energy parameters on subsurface damage layer depth are discussed in detail as shown in Fig.…”

Section: Subsurface Damage Of Dd5 Micro*holes Fabricated By Edd Processsupporting

confidence: 63%

Experimental study on fabricating micro-holes in DD5 single-crystal nickel-based superalloy using electrical discharge drilling

Gong

Sun

Jin

et al. 2020

Archiv.Civ.Mech.Eng

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The single-crystal superalloy materials have been rapidly developed and widely used in advanced thermal structural components due to their excellent comprehensive physical and chemical properties under high-temperature service conditions. However, conventional micro-hole making results in defects such as edge breakage and burr. In this study, the electrical discharge drilling (EDD) combined with helical microelectrode is first adopted to fabricate DD5 single-crystal nickel-based superalloy. The effects of tool geometry and machining parameters on subsurface damage layer, micro-hole taper, surface morphology, surface roughness and machining time were investigated in detail. Experimental results indicated that helical microelectrode can obtained smoother surface without debris deposition and thinner subsurface damage layer depth lack of micro-cracks compared with cylindrical microelectrodes. Additionally, the computational fluid dynamics model was developed to analyze working fluid movement and reveal effective debris removal mechanism of helical microelectrode. The vortices will be generated in lateral gap fluid between micro-hole and helical microelectrode and have a certain delay time. The surface roughness and dimensional precision of micro-holes fabricated by helical micro-electrodes are greatly improved and machining efficiency is also improved by 30.94% compared to cylindrical microelectrodes. This work could provide theoretical and process guidance to assist in realizing high surface quality and low subsurface damage of micro-holes obtained with EDD process.

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Section: Subsurface Damage Of Dd5 Micro*holes Fabricated By Edd Processsupporting

confidence: 63%

Experimental study on fabricating micro-holes in DD5 single-crystal nickel-based superalloy using electrical discharge drilling

Gong

Sun

Jin

et al. 2020

Archiv.Civ.Mech.Eng

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“…At the beginning of the experiment design, input EDT parameters (factors) were defined: peak current I p , voltage discharge voltage U p , pulse-on time (pulse length) P ont and pulse-off time (the length of a technological pause) P offt and other electro-discharge texturing factors (roller speed, feed rate, shape and surface area of electrodes used, material of electrodes used), which may have an effect on the monitored target values of finishing rollers Ra T,FR and Pc T,FR [9,[20][21][22].…”

Section: Design Of Experiments Materials and Methodsmentioning

confidence: 99%

“…Thus, the assumed mean target roughness value of finishing rollers Ra T,CL,FR = 1.6 × Ra UCL,SS ≈ 2.5 µm. The lower limit of the target roughness value of the designed experiment was set at 2/3 of the upper zone of the maximum roughness value of the sheet metal surface required by the automaker Volkswagen [22,23], i.e., Ra T,CL,FR = Ra UCL,SS − 1/3T SS,Ra = 1.53 µm. The upper limit of the target roughness value of the designed experiment was designed to be 3.8 µm (Ra UCL,FR = 3.8 µm) also taking into account the roughness tolerance of the working rollers T FR,Ra .…”

Section: Design Of Experiments Materials and Methodsmentioning

confidence: 99%

Optimization of Electro-Discharge Texturing Parameters for Steel Sheets’ Finishing Rollers

2020

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Exterior car-body parts are made of steel or aluminum sheets. Their formability and appearance after painting depends not only on the mechanical properties but also on their surface texture. The surface roughness characteristics, the roughness average Ra and the peak count Pc per centimeter depend on the texture of rolling mill's finishing rollers, their wear and the degree of removal by the rolling mill. The research was carried out on heat-treated finishing rollers on the surface of which a controlled texture was created by changing the electro-discharge texturing (EDT) parameters. Parameters and the number of electro-discharge texturing experiments were optimized using full four-factor experiment techniques at the upper and lower levels of the parameters in the form of 2 4 . The significance of the impact of individual EDT parameters and their interactions was identified based on the variance results. The ANOVA variance analysis results confirmed that the roughness Ra and the peak count Pc depend primarily on peak current (I p ), discharge peak voltage (U p ), pulse on time (P ont ) and pulse off time (P offt ). Optimization of the effect of the above parameters on the target roughness Ra T,FR values and the peak count Pc T,FR of finishing rollers was performed by the response surface methodology (RSM). Obtained regression models describe relationships between the input parameters of the electro-discharge texturing of finishing rollers and the output characteristics of the Ra T,FR and the Pc T,FR texture to a very high degree. The reliability of the electro-discharge texturing process of working rollers was assessed using the process capability index C pk .

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“…Zhang et al [7] introduced a new concept called medium speed wire electrical discharge machining of SKD11 and analyzed the results of material removal rate (mrr) and surface roughness (Ra) with the assistance of response surface methodology (RSM) associated with Back Propagation Neural Network (BPNN)-Genetic Algorithm (GA) techniques. Sun et al [8,9] described the effect of multi cut strategy on the fabrication of microelectrodes by adopting low-speed wire electrical discharge turning (LS-WEDT) and furthermore, the author compared the surface characteristics of WEDTed surfaces with WEDMed surfaces. Some researchers have reported the experimental investigations of process parameters, wire vibrations, wire lag, hybrid machining and process monitoring control in WEDM [8][9][10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

“…Sun et al [8,9] described the effect of multi cut strategy on the fabrication of microelectrodes by adopting low-speed wire electrical discharge turning (LS-WEDT) and furthermore, the author compared the surface characteristics of WEDTed surfaces with WEDMed surfaces. Some researchers have reported the experimental investigations of process parameters, wire vibrations, wire lag, hybrid machining and process monitoring control in WEDM [8][9][10][11][12][13]. Ibrahim et al [14] reviewed comprehensively about the influence of various wire electrode materials and its properties on WEDMed parts.…”

Section: Introductionmentioning

confidence: 99%

Investigation on machining and surface characteristics of AA5083 for cryogenic applications by adopting trim cut in WEDM

Selvakumar¹,

Kuttalingam²,

Prakash³

2018

J Braz. Soc. Mech. Sci. Eng.

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This paper presents the experimental investigation on wire electrical discharge machining (WEDM) of aluminum alloy 5083 (AA5083), an exotic material widely used for cryogenic applications. In this work, an attempt has been made primarily to examine the influence of number of trim cuts on WEDM for the following responses: cutting speed, surface roughness, corner error and dimensional shift. AA5083 is one of the predominant materials used in cryogenic applications. It is inevitable to comprise the inherent property and surface quality of the material in cryogenic conditions. Hence, it is identified that cutting AA5083 in WEDM is a potential process. Taguchi methodology has been used for conducting the experiments. The present work has been focused on satisfying the customer needs and demands of acquiring the expected surface quality with maximum productivity. Experimental results proved that the rough cut followed with one optimal trim cut produces maximum cutting speed with good surface quality. Besides, an expression has been derived for calculating average cutting speed and effective cutting speed in trim cuts. Furthermore, the surface integrity of the rough cut and trim cut is compared and discussed with the SEM micrographs.

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Experimental study on surface characteristics and improvement of microelectrode machined by low speed wire electrical discharge turning

Cited by 18 publications

References 23 publications

Experimental study on fabricating micro-holes in DD5 single-crystal nickel-based superalloy using electrical discharge drilling

Experimental study on fabricating micro-holes in DD5 single-crystal nickel-based superalloy using electrical discharge drilling

Optimization of Electro-Discharge Texturing Parameters for Steel Sheets’ Finishing Rollers

Investigation on machining and surface characteristics of AA5083 for cryogenic applications by adopting trim cut in WEDM

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