Surface and Subsurface Layers Defects Analysis After WEDM Affecting the Subsequent Lifetime of Produced Components

Mouralová, Kateřina; Prokeš, Tomáš; Beneš, Libor

doi:10.1007/s13369-019-03887-7

Cited by 15 publications

(14 citation statements)

References 27 publications

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“…A 10 mm prism semi-product was used for the experiment, with samples, microstructure and chemical composition analysis (EDX, Lyra 3, Tescan, Brno, Czech Republic) of the semi-product shown in Figure 1. on the effect of heat treatment on the occurrence of defects [11,19], the effect of section orientation by a semi-product [11,20] and the effect of the material used [21].…”

Section: Experimental Materialsmentioning

confidence: 99%

“…The knowledge of the state of the subsurface layer is a key aspect necessary to determine and assess the proper functionality of a manufactured component and its expected service life. In fact, if there are defects in the subsurface area in the form of cracks, such as X210Cr12 steel and their various heat treatments [11] or in the form of burnt cavities, such as Creusabro 4800 [29], Hardox 400, or Hadfield steel [21], it is very likely that the correct functionality or service life of a component will not be maintained. For this reason, it is always necessary to know whether it is necessary to optimize the machine setting parameters, the cutting direction of the semi-product or other aspects to eliminate these subsurface defects or not.…”

Section: The Analysis Of Surface and Subsurface Areamentioning

confidence: 99%

“…WEDM technology is very difficult to optimize due to a large number of parameters entering the machining process, and the optimization is usually aimed at maximizing the cutting speed and the quality of the machined surface. Considering the number of input factors affecting the speed of cutting and the quality of the surface and subsurface layers, extensive research has been carried out on the effect of heat treatment on the occurrence of defects [11,19], the effect of section orientation by a semi-product [11,20] and the effect of the material used [21].…”

Section: Introductionmentioning

confidence: 99%

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Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

et al. 2020

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The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out to optimize the machining of the copper alloy Ampcoloy 35, which is particularly useful in plastic injection moulds. Within the study, a half-factor experiment of 25-1 with 10 axial points and seven central points of a total of 33 rounds was carried out, which was focused on the response monitoring of the input factors in the form of the machine parameters setup: gap voltage, pulse on time, pulse off time, discharge current, and wire speed. Based on the study of the response in the form of cutting speed and surface topography, their statistical models were created, while the optimal setting of machine parameters was determined to maximize the cutting speed and minimize the topography parameters. Further, a detailed cross-sectional analysis of surface and subsurface layer morphology was performed using electron microscopy including chemical composition analysis. In order to study microstructural changes in the material at the atomic level, a lamella was created, which was then studied using a transmission electron microscope.

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Section: Experimental Materialsmentioning

confidence: 99%

Section: The Analysis Of Surface and Subsurface Areamentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

et al. 2020

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“…Die-sinking EDM is a technological process where it is necessary to ensure machining efficiency and maximize the material removal rate while maintaining excellent surface and subsurface quality. To investigate in detail all the input factors affecting the erosion process of various types of steel, extensive research has been conducted including the influence of the cutting orientation of the semi-product, depending on its heat treatment for X210Cr12 steel [21], Hadfield machinability analysis [22], Creusabro [23], and Hardox steel [24] by using the design of experimentsand analysis of durability due to the occurrence of surface and subsurface defects [25]. The purpose of this study was a complex analysis of EDM-machined surfaces of individual experimental samples concerning the state of the subsurface area and formed defects.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2020

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Die-sinking electric discharge machining (EDM) is an indispensable technological operation, especially in the production of molds and all internal and external shapes and cavities. For this reason, the effect of machine parameter settings (open-voltage, pulse current, pulse on time, and pulse off time) on the machining of two types of steels, 1.2363 and 1.2343ESR, was carefully investigated using graphite or copper electrodes in 10 mm × 10 mm or 100 mm × 100 mm shapes. For this purpose, a two-level half factor experiment was performed with one replication at the corner points and two replications at the central points, with a total of 80 rounds. The subject of the evaluation was the topography and morphology of machined surfaces including a detailed analysis of surface and subsurface defects in the form of cracks including the creation of regression equations describing the probability of crack occurrence. Furthermore, a study of the local hardness change in the subsurface area was performed, and lamellas were also made and studied by transmission electron microscopy. It has been found that by using die-sinking EDM, it is possible to effectively predict the probability of cracking on machined surfaces and also on machine 1.2363 and 1.2343ESR steels with a very good surface quality of Ra 1.9 and 2.1 µm using graphite electrodes. These findings will ensure the production of parts with the required surface quality without cracks, which is a crucial aspect for maintaining the required functionality and service life of the parts.

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“…The machining length in the form of cutting speed can be reduced primarily by the suitable optimization of the machine parameters settings, while also taking into account the resulting quality of the machined surface and also the dimensional accuracy. To optimize the WEDM process for different materials, many extensivedesigns of experiments and studies have been performed, e.g., optimizing the machining of Creusabro [6], Hardox [7] or Hadfield steels [8] and aluminium alloys 7475-T7351 [9], or finding the occurrence of subsurface defects depending on their lifetime [10]. The aim of this study was to present the results of a detailed and extensive optimization process for machining the Nimonic C 263 super alloy using WEDM, and no such extensive experiment has been performed with this material in similar studies.…”

Section: Introductionmentioning

confidence: 99%

Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

et al. 2020

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Wire electrical discharge machining (WEDM) is an unconventional and very efficient technology for precision machining of the Nimonic C 263 super alloy, which is very widespread, especially in the energy, aerospace and automotive industries. Due to electrical discharge, defects in the form of cracks or burned cavities often occur on the machined surfaces, which negatively affect the correct functionality and service life of the manufactured components. To increase the efficiency of the machining of Nimonic C 263 using WEDM, in this study, extensive design of experiments was carried out, monitoring input factors in the form of machine parameters like Pulse off time, Gap voltage, Discharge current, Pulse on time and Wire feed, the output of which was comprehensive information about the behaviour of such machined surfaces, which allowed the optimization of the entire machining process. Thus, the optimization of the Cutting speed was performed in relation to the quality of the machined surface and the machining accuracy, as well as an analysis of the chemical composition of the machined surfaces and a detailed analysis of the lamella using a transmission electron microscope. A detailed study of the occurrence of surface or subsurface defects was also included. It was found that with the help of complex optimization tools, it is possible to significantly increase the efficiency of the machining of the Nimonic C 263 super alloy and achieve both financial savings in the form of shortened machine time and increasing the quality of machined surfaces.

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Surface and Subsurface Layers Defects Analysis After WEDM Affecting the Subsequent Lifetime of Produced Components

Cited by 15 publications

References 27 publications

Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

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

Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

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