Numerical prediction of heat affected layer in the EDM of aeronautical alloys

Izquierdo, B.; Plaza, Soraya; Sánchez, J.A.; Pombo, I.; Ortega, Naiara

doi:10.1016/j.apsusc.2012.07.124

Cited by 60 publications

(20 citation statements)

References 17 publications

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“…Based on the results of FEM and experimental observations, a numerical analysis has been done assessing the contribution of input parameters on the efficiency of plasma channel in removing the molten material from workpiece and tool at the end of each discharge. Recast layer distribution in EDM of inconel 718 has been simulated by Izquierdo et al [14] and predicted the recast layer with less than 4.5 μm using FEM. Zhang et al [15] proposed a novel method of determining the energy distribution and plasma diameter of EDM by comparing the boundary of the melted material obtained from metallographic and finite element method.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V

Kuriachen

Varghese

Somashekhar³

et al. 2015

Int J Adv Manuf Technol

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The aim of the present work is to develop a predictive thermal model based on heat transfer principle for the simulation of single-spark microelectric discharge machining (μ-EDM). The three-dimensional model is solved using finite volume method (FVM). It utilizes the Gaussian distribution of heat flux, percentage distribution of energy among the workpiece, tool electrode, and dielectric to perform transient thermal analysis to predict the crater geometry and temperature distribution in the workpiece at different voltages and capacitance values along the x, y, and z directions. The experiments were performed for single-spark discharge using a resistorcapacitor (RC) circuit with titanium alloy (Ti-6Al-4V) as workpiece material and tungsten carbide as tool electrode. The experimental crater dimensions were measured by using a scanning electron microscope (SEM). The model is validated by comparing the predicted temperature distribution with the published results and also with experimental results. Results show that the trends predicted by the model are logical and match fairly well with the experimental trends.

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Section: Introductionmentioning

confidence: 99%

Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V

Kuriachen

Varghese

Somashekhar³

et al. 2015

Int J Adv Manuf Technol

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“…Among non-traditional machining process electric discharge machining (EDM) is considered as relatively good alternative having no material hardness and channel shape restrictions [224,225]. But there are also number of problems linked with EDM and wire-EDM such as low productivity, high tool wear rate, lack of precision due to tool wear, unsuitable for batch production or multi-channels [226], thick recast layer (from 2.5 to 30 µm) [227], heat affected layer of 40-100 um [227], thick white layers (6-8 µm) with micro-cracks [228], poor surface integrity [229] and necessary post processing requirements [230]. Chemical etching is another alternative for the fabrication of micro-channels but it offers troubles of having high aspect-ratio micro-channels [231].…”

Section: Fabrication Techniquesmentioning

confidence: 99%

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Darwish

Ahmed

Al‐Ahmari

2016

Advanced Structured Materials

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Laser beam machining (LBM) has proven its applications and advantages over almost all the range of engineering materials. It offers its competences from macro machining to micro and nano-machining of simple-to-complex shapes. The flipside of LBM is the existence of universal problems associated with its thermal ablation mechanism. In order to alleviate or reduce the inherent problems of LBM, a massive research has been done during the past decade and in turn build a relatively new route of laser-hybrid processes. The hybrid approaches in laser ablation have demonstrated much improved results in terms of material removal rate, surface integrity, geometrical tolerances, thermal damage, metallurgical alterations and many more. This chapter reviews the research work carried out so far in the area of LBM and its hybrid processes for different materials and shapes.

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“…When the end of the discharge, due to the inertia of the liquid medium, the bubble continues to expand resulting in a sharp reduction in the pressure inside the bubble, the formation of a local vacuum, so that the molten metal material from the crater splash and was thrown. An equivalent temperature T eq is adopted by B Izquierdo et al 2 to describe the removal criterion that materials with temperature higher than T eq will be removed. In this research, the workpiece material with a temperature above its melting point will be removed during the machining process.…”

Section: Criterion For Materials Removalmentioning

confidence: 99%

“…B Izquierdo et al 2 learned that for nickel-based alloys, it will be more meaningful to research the surface topography due to the demanding requirements of its industrial application areas, such as turbine blades, aircraft, liquid fuel rocket motor, nuclear reactors, and pumps. Its poor thermal conductivity, high-strength values, and self-hardening behavior lead to many tough challenges such as severe plastic deformation, tool wear, high cutting force, and temperature.…”

Section: Introductionmentioning

confidence: 99%

Formation mechanism of surface topography in low-speed wire electrical discharge machining Inconel 718 and its on-line prediction based on acoustic emission technology

Wang

Yang

et al. 2017

Advances in Mechanical Engineering

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The mechanism of surface topography formation of Inconel 718 in low-speed wire electrical discharge machining was studied, and its on-line prediction based on acoustic emission detection technology is carried out. An optimized truncated cone-shaped thermal conduction model considering the scattering velocity difference between electrons and ions was put forward. Based on this model, discharge craters and temperature variation at different discharge energy conditions were systematically discussed in finite element analysis. Experimentally, five machining regimes that are reduced in accordance with the discharge energy were conducted with acoustic emission detection technology in low-speed wire electrical discharge machining. A novel denoising method has been proposed, which combines filtering analysis and Fast Fourier Transform. The experimental results indicate that acoustic emission testing technique provides great technical support in researching the discharge energy variation rule in low-speed wire electrical discharge machining. It is also concluded that the change trends of the theoretically calculated temperature in the discharge channel and acoustic emission signal root mean square and the surface roughness value and the acoustic emission signal root mean square show a similar exponential growth law. A regression equation about the arithmetic mean roughness (R a ) values and root mean square values of acoustic emission is established to predict surface roughness value R a whose error is less than 1%.

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Numerical prediction of heat affected layer in the EDM of aeronautical alloys

Cited by 60 publications

References 17 publications

Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V

Three-dimensional numerical simulation of microelectric discharge machining of Ti-6Al-4V

Laser Beam Machining, Laser Beam Hybrid Machining, and Micro-channels Applications and Fabrication Techniques

Formation mechanism of surface topography in low-speed wire electrical discharge machining Inconel 718 and its on-line prediction based on acoustic emission technology

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