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

Burek, Jan; Babiarz, Robert; Buk, Jarosław; Sułkowicz, Paweł; Krupa, Krzysztof

doi:10.3390/ma14030562

Cited by 20 publications

(8 citation statements)

References 43 publications

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“…After one-time rough and finish machining, the profile error of the Inconel 718 turbine disk slots reached 6 5 ; 6 25 mm, the surface roughness Ra was about 0.8-1.25 mm, and the thickness of the surface recast layer did not exceed 5 mm. 46 Klocke et al used a nickelplated copper wire and monitoring technology for wire-EDM electrical parameters to improve the machining quality. The experimental results were obtained that the profile error of the Inconel 718 turbine disk slots can reach 6 5 mm, the surface roughness Ra was less 43 than 0.8 mm, and the thickness of surface recast layer was about 2 mm after one-time rough machining and two-time finish machining, 33 as shown in Figure 10.…”

Section: Wire-edmmentioning

confidence: 99%

A brief review on the status of machining technology of fir-tree slots on aero-engine turbine disk

Wenshuo

et al. 2022

Advances in Mechanical Engineering

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The machining precision and its consistency of turbine disk fir-tree slots have a direct influence on the performance of aero-engine rotor components. However, the structural dimensions of fir-tree slot are small, and the cutting performance of materials is extremely poor, which lead to great difficulty in machining and very few available machining methods. With the application of new materials in the aero-engines, the machining precision and quality requirements of fir-tree slots are further improved. Therefore, many research achievements on the high-efficiency, high-quality and low-cost machining technology of turbine disk fir-tree slots have been obtained. By summarizing and classifying the machining methods of aero-engine turbine disk fir-tree slots, a brief review on the characteristics of different methods are presented in detail, which provide a reference for selecting the appropriate machining method of turbine disk fir-tree slots in the field of aviation manufacturing. Meanwhile, combined with the research and application status of machining technology of turbine disk fir-tree slots, it is presented that multi-process compound machining is an effective method to realize high-efficiency, high-quality and low-cost precision machining of turbine disk fir-tree slots, such as wire electro discharge machining (wire-EDM) and profiled grinding, wire electrochemical machining (wire-ECM) and profiled grinding, wire-EDM and broaching, milling and broaching.

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Section: Wire-edmmentioning

confidence: 99%

A brief review on the status of machining technology of fir-tree slots on aero-engine turbine disk

Wenshuo

et al. 2022

Advances in Mechanical Engineering

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“…In the place of discharge, a crater is formed. The complexity of the physical phenomena of the material removal process causes difficulties in identifying the influence of WEDM parameters on the effects of machining [32][33][34][35][36][37][38]. A significant part of the research has focused on the modeling of WEDM and its optimization [39][40][41][42][43][44].…”

Section: Introductionmentioning

confidence: 99%

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

Oniszczuk-Świercz

Świercz

2023

Materials

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The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed.

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“…Among the treatment conditions of the micro-WEDM process that significantly affect the morphology and roughness of the surface is the number of trim offsets. Sharma et al [ 14 ] and Burek et al [ 15 ] indicated that surface morphology significantly depends on the number of machining passes. The use of additional passes allows a decrease in the parameters of surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Prediction Models of the Microwire EDM Process of Inconel 718 Using ANN and RSM Methods

2022

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Precise machining of micro parts from difficult-to-cut materials requires using advanced technology such as wire electrical discharge machining (WEDM). In order to enhance the productivity of micro WEDM, the key role is understanding the influence of process parameters on the surface topography and the material’s removal rate (MRR). Furthermore, effective models which allow us to predict the influence of the parameters of micro-WEDM on the qualitative effects of the process are required. This paper influences the discharge energy, time interval, and wire speed on the surface topography’s properties, namely Sa, Sk, Spk, Svk, and MRR, after micro-WEDM of Inconel 718 were described. Developed RSM and ANN model of the micro-WEDM process, showing that the discharge energy had the main influence (over 70%) on the surface topography’s parameters. However, for MRR, the time interval was also significant. Furthermore, a reduction in wire speed can lead to a decrease in the cost process and have a positive influence on the environment and sustainability of the process. Evaluation of developed prediction models of micro-WEDM of Inconel 718 indicates that ANN had a lower value for the relative error compared with the RSM models and did not exceed 4%.

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

Cited by 20 publications

References 43 publications

A brief review on the status of machining technology of fir-tree slots on aero-engine turbine disk

A brief review on the status of machining technology of fir-tree slots on aero-engine turbine disk

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

Evaluation of Prediction Models of the Microwire EDM Process of Inconel 718 Using ANN and RSM Methods

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