OBRABOTKAMETALLOV Vol. 27 No. 1 2025 technology Improvement the manufacturing quality of new generation heat-resistant nickel alloy products using wire electrical discharge machining Evgeniy Shlykov a, *, Timur Ablyaz b, Vladimir Blokhin c, Karim Muratov d Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation a https://orcid.org/0000-0001-8076-0509, Kruspert@mail.ru; b https://orcid.org/0000-0001-6607-4692, lowrider11-13-11@mail.ru; c https://orcid.org/0009-0009-2693-6580, warkk98@mail.ru; d https://orcid.org/0000-0001-7612-8025, Karimur_80@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2025 vol. 27 no. 1 pp. 34–47 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.1-34-47 ART I CLE I NFO Article history: Received: 12 December 2024 Revised: 19 December 2024 Accepted: 28 December 2024 Available online: 15 March 2025 Keywords: Wire electrical discharge machining Surface roughness Accuracy Microcracks Surface layer Cyclic testing Funding The research was financially supported by the Russian Science Foundation grant No. 23-79-01224, https://rscf.ru/ project/23-79-01224/. ABSTRACT Introduction. The paper presents the results of an experimental study on the quantitative and qualitative evaluation of the surface after wire electrical discharge machining (WEDM). The purpose of this study is an experimental investigation with qualitative and quantitative analysis of surface defects in samples made of a heatresistant nickel alloy VV751P after WEDM. Methods of research. Samples for the study with a specific geometry were obtained by the wire electrical discharge machining method in 4 modes. The operating parameters were: workpiece height (h, mm), pulse-on time (Ton, μs), and pulse-off time (Toff, μs). The samples were studied using a Hitachi S-3400N electron microscope in backscattered electron mode at 25 kV. Surface topography after electrical discharge machining was evaluated using a laser scanning microscope (LSM) LextOLS4000. Cyclic tests were performed on a universal testing machine Biss-00-100 at a test frequency of 20 Hz in a symmetrical cycle (R = −1). Results and discussion. The defective (white) layer of samples was analyzed. It is established that during wire electrical discharge machining the thickness of defective white layer is within 10 µm, both after processing in minimum and maximum mode. The surface quality index (surface roughness Ra) was analyzed. It was found that the average value of surface roughness parameter Ra is 1.62 μm when processing samples with a height of 10 mm. When the sample height increases, the surface roughness value reaches 2.6 μm after processing in minimum mode and 3.4 μm after processing in maximum mode. It is established that with an increase in workpiece height, the number of microcracks on the surface of the product increases, which is associated with the intensification of the interaction of single pulses with the processed surface. As a result of the study, it is found that at a loading amplitude of 400 MPa, an average value of the number of cycles reaches 1.50E + 05 cycles. A decrease in the number of cycles is observed with an increase in the amplitude of the loading cycles. For citation: Shlykov E.S., Ablyaz T.R., Blokhin V.B., Muratov K.R. Improvement the manufacturing quality of new generation heat-resistant nickel alloy products using wire electrical discharge machining. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 1, pp. 34–47. DOI: 10.17212/1994-6309-2025-27.1-34-47. (In Russian). ______ * Corresponding author Shlykov Evgeniy S., Ph.D. (Engineering), Associate Professor Perm National Research Polytechnic University, 29 Komsomolsky prospekt, 614990, Perm, Russian Federation Tel.: +7 961 759-88-49, e-mail: Kruspert@mail.ru Introduction Modern industry faces constant requirements for product quality. The introduction of new-generation alloys results in increased physical and mechanical properties of products. For example, the introduction of the granulated, heat-resistant nickel alloy VV751P into production has led to increased stability of aviation products in high-temperature environments without sacrificing their mechanical properties. Products made of heat-resistant alloy VV751P offer extended service life and improved cyclic durability [1‑3]. The modern aircraft engine building industry predominantly uses machining for manufacturing products. Introducing new materials significantly complicates the serial production process. Heat-resistant materials’ machining presents several technological and economic disadvantages. The high hardness of heat-resistant alloys causes build-up on the cutting tool, reducing tool durability and lowering machining accuracy. Other
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