Investigation of the influence of process parameters of wire electrical discharge machining using coated brass on the surface roughness of Inconel 718

Oniszczuk-Świercz, Dorota; Świercz, Rafał; Nowicki, Rafał; Kopytowski, Adrian; Dąbrowski, Ł.

doi:10.1063/1.5056283

Cited by 8 publications

(5 citation statements)

References 20 publications

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“…Klocke et al [ 27 ] presented the concept of using WEDM in manufacturing fir tree slots. Oniszczuk-Świercz et al [ 28 ] investigated the effect of WEDM process parameters on the surface quality of Inconel 718 using coated brass wire. Sharma et al [ 29 , 30 ] investigated the possibility of using WEDM in manufacturing Inconel 706 aircraft engine parts.…”

Section: Introductionmentioning

confidence: 99%

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

et al. 2021

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Servicing aircraft engines sometimes requires manufacturing only a single piece of a given part. Manufacturing a turbine disc using traditional methods is uneconomical. It is necessary to use a different machining method recommended for small lot production. One of the proposed methods is WEDM (wire electrical discharge machining). The article presents the results of the research on finishing WEDM of Inconel 718 turbine disc fir tree slots. The influence of infeed, mean gap voltage, peak current, pulse off-time, and discharge energy on the shape accuracy, surface roughness, microcracks, and the white layer thickness were determined. Mathematical models were developed based on the DoE (Design of Experiment) analysis. The statistical significance of the models was verified with the ANOVA (Analysis of Variance) test. The machining parameters control methods that allow achieving the required shape accuracy, surface roughness, and surface layer condition were presented. The obtained surface roughness was Ra = 0.84 μm, the shape accuracy of the slot in the normal-to-feed direction was Δd = 0.009 μm, the profile shape accuracy was Δr = 0.033 μm, and the thickness of recast (white) layer was approximately 5 μm.

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Section: Introductionmentioning

confidence: 99%

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

et al. 2021

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“…This indicates incomplete removal of the unevenness after roughing machining. Oniszczuk et al arrived at similar conclusions [37]. The value of the roughness peaks Spk is lower for lowest energy of discharge.…”

Section: Surface Roughnessmentioning

confidence: 62%

Surface Topography of Inconel 718 Alloy in Finishing WEDM

Buk¹

2022

Adv. Sci. Technol. Res. J.

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The properties of Iconel 718 determine its application for parts operating in extremely tough conditions. The diffi culties 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 fi nishing machining. The literature indicates that the peak current is the main parameter responsible for shaping the machined surface in fi nishing WEDM. Furthermore, few works focus on the electrode's infeed, in particular there are not many papers regarding the infl uence of the infeed on the machined surface parameters. Therefore, the paper aims to investigate on the infl uence of the peak current and infeed during fi nishing 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 HV 0,01 measured by Berkovich tip was recorded to determine the size of a heat aff ected zone (HAZ). The correlation between the peak current I c and the infeed z regarding the machined surface quality was presented.

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“…The machining process consists of material removal as a result of melting and evaporation due to electrical discharges between the tool and the workpiece [ 105 , 106 , 107 ]. WEDM is a trepan-type technology, in which removing a significant amount of blank volume requires the erosion of a small amount of material [ 93 , 108 ]. In comparison with EDM, much lower discharge energy is needed in wire electrical discharge machining.…”

Section: Methods Of Manufacturing Fir Tree Slots Of the Turbine Discsmentioning

confidence: 99%

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

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This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.

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Investigation of the influence of process parameters of wire electrical discharge machining using coated brass on the surface roughness of Inconel 718

Cited by 8 publications

References 20 publications

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

The Accuracy of Finishing WEDM of Inconel 718 Turbine Disc Fir Tree Slots

Surface Topography of Inconel 718 Alloy in Finishing WEDM

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

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