Investigation into erosion rate of AISI 4340 steel during wire electrical discharge turning process

doi:10.1080/10910344.2017.1365890

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Investigation into erosion rate of AISI 4340 steel during wire electrical discharge turning process

Journal Article•DOI•

Investigation into erosion rate of AISI 4340 steel during wire electrical discharge turning process

Abimannan Giridharan¹, G.L. Samuel²•Institutions (2)

VIT University¹, Indian Institute of Technology Madras²

04 Mar 2018-Machining Science and Technology (Taylor & Francis)-Vol. 22, Iss: 2, pp 287-298

TL;DR: In this article, the wire electrical discharge turning (WEDT) process was developed to generate cylindrical form on any electrically conductive material applied in aerospace and automotive industry.

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Abstract: Wire electrical discharge turning (WEDT) process was developed to generate cylindrical form on any electrically conductive material applied in aerospace and automotive industry. The mechani...

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Journal Article•DOI•

Development of the Cylindrical Wire Electrical Discharge Machining Process

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Jun Qu¹, Albert J. Shih¹, Ronald O. Scattergood¹•Institutions (1)

North Carolina State University¹

11 Nov 2001-Manufacturing Engineering

TL;DR: In this paper, the design of a precise, flexible, and corrosion-resistant underwater rotary spindle has been introduced to generate cylindrical forms on hard, difficult-to-machine materials.

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Abstract: Results of applying the wire Electrical Discharge Machining (EDM) process to generate precise cylindrical forms on hard, difficult-to-machine materials are presented. The design of a precise, flexible, and corrosion-resistant underwater rotary spindle is first introduced. A detailed spindle error analysis identifies the major sources of error at different frequency spectrum. The spindle has been added to a conventional two-axis wire EDM machine to enable the generation of free-form cylindrical geometries. The mathematical model for material removal rate of the free-form cylindrical wire EDM process is derived. Experiments were conducted to explore the maximum material removal rate for cylindrical and 2D wire EDM of carbide and brass work-materials. Compared to the conventional 2D wire EDM of the same work-material, higher maximum material removal rates may be achieved in the cylindrical wire EDM, possibly due to better debris flushing condition.

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101 citations

Journal Article•DOI•

State of the art in processing of shape memory alloys with electrical discharge machining: A review:

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Ranjit Singh¹, Ravi Pratap Singh¹, Rajeev Trehan¹•Institutions (1)

Dr. B. R. Ambedkar National Institute of Technology Jalandhar¹

01 Feb 2021

TL;DR: Shape memory alloys (SMAs) have been well known for their superior and excellent properties which makes them an eligible candidate of paramount importance in real-life industrial applications such as as discussed by the authors.

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Abstract: Shape memory alloys (SMAs) have been well known for their superior and excellent properties which makes them an eligible candidate of paramount importance in real-life industrial applications such ...

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27 citations

Journal Article•DOI•

Study on crater depth during material removal in WEDC of Ni-rich nickel–titanium shape memory alloy

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Himanshu Bisaria¹, Pragya Shandilya¹•Institutions (1)

Motilal Nehru National Institute of Technology Allahabad¹

01 Mar 2019-Journal of The Brazilian Society of Mechanical Sciences and Engineering

TL;DR: In this paper, the individual effect of wire electrical discharge cutting (WEDC) process parameters, namely discharge energy density, wire feed rate, spark frequency, wire tension, and spark gap voltage on average crater depth, material removal rate (MRR), and metallographic changes of Ni55.95Ti44.05 shape memory alloy (SMA), was revealed.

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Abstract: The objective of this experimental investigation is to reveal the individual effect of wire electrical discharge cutting (WEDC) process parameters, namely discharge energy density, wire feed rate, spark frequency, wire tension, and spark gap voltage on average crater depth, material removal rate (MRR), and metallographic changes of Ni55.95Ti44.05 shape memory alloy (SMA). The analysis of crater size during material removal in WEDC has been also discussed in this study. The three-dimensional surface topography at higher discharge energy density divulges the formation of deeper and wider craters with high surface roughness on the machined surface compared to lower discharge energy density. MRR and average crater depth increase with the increase in discharge energy density and decrease with the increase in spark frequency and spark gap voltage, whereas wire feed rate and wire tension have the trivial effect. The analysis of X-ray diffraction peaks of the machined surface shows the presence of various compounds such as NiTi, TiO, TiO2, Ni4Ti3, CuZn, Cu2NiZn, NiTiO3, and NiZn and tensile residual stress.

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25 citations

Cites methods from "Investigation into erosion rate of ..."

...(12): According to the method proposed by Giridharan and Samuel [24], the crater diameter in terms of discharge energy (E), latent heat of melting (Lm), and latent heat of vaporization (Lv) of workpiece material and density (ρ) can be given according to Eq....
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... (12): According to the method proposed by Giridharan and Samuel [24], the crater diameter in terms of discharge energy (E), latent heat of melting (Lm), and latent heat of vaporization (Lv) of workpiece material and density (ρ) can be given according to Eq....
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...Giridharan and Samuel [15] have also investigated the influence of discharge energy on machinability of AISI 4340 steel in WEDM....
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Journal Article•DOI•

Multi-objective optimization of roundness, cylindricity and areal surface roughness of Inconel 825 using TLBO method in wire electrical discharge turning (WEDT) process

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Jees George¹, R. Manu¹, Jose Mathew¹•Institutions (1)

National Institute of Technology Calicut¹

01 Sep 2019-Journal of The Brazilian Society of Mechanical Sciences and Engineering

TL;DR: In this paper, the effect of machining parameters in WEDT process on the output responses are studied using experiments based on Box-Behnken design. But the main objective of this study is to identify the optimum process parameters required to obtain improved geometry of the turned components with respect to roundness, cylindricity and areal surface roughness.

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Abstract: Wire electrical discharge turning (WEDT) is a non-conventional machining process, which was developed to machine cylindrical components on difficult-to-machine, but electrically conductive materials with high precision. In the present work, roundness, cylindricity and areal surface roughness of the parts created by WEDT process are investigated. Inconel 825 was the material chosen for the present study. The main objective of this study is to identify the optimum process parameters required to obtain improved geometry of the turned components with respect to roundness, cylindricity and areal surface roughness. The effects of machining parameters in WEDT process on the output responses are studied using experiments based on Box–Behnken design. ANOVA has been performed to study the effect of process parameters on the output responses. A novel optimization approach is used to identify the optimum parameters for each response. Teaching learning-based optimization (TLBO) is used to optimize the process, considering the three output responses in order to improve the quality of the turned products. Validation experiments were conducted, and the predicted results were verified. It is observed that the roundness, cylindricity and areal surface roughness of components machined with WEDT process obtained from TLBO technique and validation experiments are in close agreement. The surface morphology of the samples having maximum and minimum Sa value was studied using SEM micrographs. Finally, a microelectrode of 185 µm diameter and 4 mm length was successfully fabricated with multiple cut strategy using the WEDT setup in order to demonstrate the process capability.

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24 citations

Journal Article•DOI•

A study of machining characteristics of AISI 4340 alloy steel by wire electrical discharge machining process

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P.S. Gowthaman, J. Gowthaman, N. Nagasundaram

01 Jan 2020-Materials Today: Proceedings

TL;DR: In this article, a noncontact erosion cutting process (WEDM) is used to cut the electrical conductive as well as nonconductive materials and it has a capability of machining parts with varying hardness, intricate shapes, contours and complex shapes.

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11 citations

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References

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Journal Article•DOI•

Three-Dimensional Micromachining by Machine Tools

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Takahisa Masuzawa¹, Hans Kurt Tönshoff•Institutions (1)

University of Tokyo¹

01 Jan 1997-CIRP Annals

TL;DR: In this article, the state-of-the-art machining technologies for three-dimensional microproducts are summarized by focusing on the methods using tools, and promising methods for machining convex and concave shapes are introduced and discussed with respect to their state of the art.

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290 citations

"Investigation into erosion rate of ..." refers methods in this paper

...The spark erosion mechanism in WEDT process is similar to that of the EDM process (Masuzawa and Tonshoff, 1997), the only difference is in WEDM a continuously travelling wire is used and the pulses are of short duration (Spur and Schonbeck, 1993), and inWEDT an additional rotary motion is given to the workpiece....
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...Turning using WEDMwas first reported while turning a shaft of 5 μm diameter (Masuzawa and Tonshoff, 1997)....
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...The spark erosion mechanism in WEDT process is similar to that of the EDM process (Masuzawa and Tonshoff, 1997), the only difference is in WEDM a continuously travelling wire is used and the pulses are of short duration (Spur and Schonbeck, 1993), and inWEDT an additional rotary motion is given to…...
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Journal Article•DOI•

Multi-objective optimization of wire-electro discharge machining process by Non-Dominated Sorting Genetic Algorithm

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Shajan Kuriakose¹, M.S. Shunmugam¹•Institutions (1)

Indian Institute of Technology Madras¹

14 Dec 2005-Journal of Materials Processing Technology

TL;DR: In this article, a multiple regression model is used to represent relationship between input and output variables and a multi-objective optimization method based on a Non-Dominated Sorting Genetic Algorithm (NSGA) was used to optimize wire-EDM process.

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242 citations

"Investigation into erosion rate of ..." refers methods in this paper

...© Taylor & Francis Group, LLC of EDM process, which uses a continuously travelling wire as tool electrode (Kuriakose and Shunmugam, 2005)....
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...of EDM process, which uses a continuously travelling wire as tool electrode (Kuriakose and Shunmugam, 2005)....
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Journal Article•DOI•

Thermo-physical modeling of die-sinking EDM process

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Shrikrishna N. Joshi¹, S. S. Pande¹•Institutions (1)

Indian Institute of Technology Bombay¹

01 Jan 2010-Journal of Manufacturing Processes

TL;DR: In this paper, the authors developed a thermo-physical model for die-sinking electric discharge machining (EDM) process using finite element method (FEM) to predict the shape of crater cavity and the material removal rate (MRR).

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213 citations

"Investigation into erosion rate of ..." refers background or methods in this paper

...SEM (Alvarez et al., 1973), profilometer (Wang et al., 1992), confocal laser scanning microscope (Schulze et al., 2004), high magnification microscope coupled with CAD software (Yoshida et al., 2011), atomic forcemicroscope (Tao et al., 2012) and three dimensional scanner (Joshi and Pande, 2010)....
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...Joshi and Pande (2010) proposed a thermo physical model to predict material removal rate (MRR) for a given discharge energy assuming 100% plasma flushing efficiency....
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...Joshi and Pande (2010) acquired the crater geometry using a three dimensional topography measuring instrument....
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..., 2012) and three dimensional scanner (Joshi and Pande, 2010)....
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Journal Article•DOI•

A finite element model of EDM based on the Joule effect

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José Duarte Marafona¹, J.A.G. Chousal¹•Institutions (1)

Faculdade de Engenharia da Universidade do Porto¹

01 May 2006-International Journal of Machine Tools & Manufacture

TL;DR: In this paper, a thermal-electrical model was developed for sparks generated by electrical discharge in a liquid media, where a cylindrical shape has been used for the discharge channel created between the electrodes.

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Abstract: A thermal–electrical model was developed for sparks generated by electrical discharge in a liquid media. A cylindrical shape has been used for the discharge channel created between the electrodes. The discharge channel being an electrical conductor will dissipate heat, which can be explained by the Joule heating effect. The amount of heat dissipated varies with the thermal–physical properties of the conductor; as a result, the maximum temperature reached is different. In the present model, the radii value of the conductor is a function of the current intensity and pulse duration. The thermal–physical values used in the model are the average of both the ambient and melting value. Copper and iron are the materials used for anode and cathode, respectively. The Finite Element Analysis (FEA) results were compared with the experimental values of the table of AGIE SIT used by other researchers [D.D. DiBitonto, P.T. Eubank, M.R. Patel, M.A. Barrufet, Theoretical models of the electrical discharge machining process—I: a simple cathode erosion model, Journal of Applied Physics, 66(9) (1989) 4095–4103; M.R. Patel, M.A. Barrufet, P.T. Eubank, D.D. DiBitonto, Theoretical models of the electrical discharge machining process—II: the anode erosion model, Journal of Applied Physics, 66(9) (1989) 4104–4111; P.T. Eubank, M.R. Patel, M.A. Barrufet, B. Bozkurt, Theoretical models of the electrical discharge machining process—III: the variable mass, cylindrical plasma model, Journal of Applied Physics, 73(11) (1993) 7900–7909]. In order to show the universality of the model it was obtained results for all current intensity values of the table. The Tool Wear Ratio (TWR) and Material Removal Rate (MRR) as well as surface roughness results agree reasonably well with the researcher's values found for that table and itself.

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174 citations

"Investigation into erosion rate of ..." refers methods in this paper

...In this work deionized water is used as the dielectric medium and the fraction of material removed from the molten volume ‘f ’ is taken as 3% (Marafona and Chousal, 2006; Giridharan and Samuel, 2015)....
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Journal Article•DOI•

A numerical model of the EDM process considering the effect of multiple discharges

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B. Izquierdo, Jose Antonio Sánchez, S. Plaza, I. Pombo, Naiara Ortega - Show less +1 more

01 Mar 2009-International Journal of Machine Tools & Manufacture

TL;DR: In this article, a new contribution to the simulation and modelling of the electrical discharge machining process is presented, where temperature fields within the workpiece generated by the superposition of multiple discharges are numerically calculated using a finite difference schema.

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Abstract: The electrical discharge machining (EDM) process is, by far, the most popular amongst the non-conventional machining processes. The technology is optimum for accurate machining of complex geometries in hard materials, as those required in the tooling industry. However, although a large number of EDM machines are sold every year, scientific knowledge of the process is still limited. The complex nature of the process involves simultaneous interaction of thermal, mechanical, chemical and electrical phenomena, which makes process modelling very difficult. In this paper a new contribution to the simulation and modelling of the EDM process is presented. Temperature fields within the workpiece generated by the superposition of multiple discharges, as it happens during an actual EDM operation, are numerically calculated using a finite difference schema. The characteristics of the discharge for a given operation, namely energy transferred onto the workpiece, diameter of the discharge channel and material removal efficiency can be estimated using inverse identification from the results of the numerical model. The model has been validated through industrial EDM tests, showing that it can efficiently predict material removal rate and surface roughness with errors below 6%.

...read moreread less

171 citations

"Investigation into erosion rate of ..." refers background in this paper

...However, the studies reveal that conducting single spark test is tedious and published models based on single spark test reveals different discharge conditions compared to that of discharge that occurs in continuous spark EDM process (Izquierdo et al., 2009)....
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...Izquierdo et al. (2009) proposed a finite difference-based multi-spark thermal model for predicting material removal....
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