OBRABOTKA METALLOV
METAL WORKING AND MATERIAL SCIENCEPrint ISSN: 1994-6309 Online ISSN: 2541-819X
Introduction. In order to improve operational properties of the manufactured product range in engineering, materials, which have enhanced physical and mechanical properties, are used. The application of such materials makes it possible to manufacture the items of small dimensions, but with high functionality. When processing such materials, significant wear of the cutting tool occurs, and when processing items of complex profile, it is necessary to use additional equipment. These factors increase the cost of manufacturing suitable products. For the processing of such products, it is advisable to use electrophysical processing methods, one of which is the technology of wire-cutting electrodischarge maching (EDM). The paper is devoted to theoretical and regression modeling of the width of the cut during EDM difficult to process materials. Subjects of research are: the magnitude of the interelectrode gap, the accuracy of EDM hard-to-handle materials. The aim of the work is to increase the accuracy of the process of EDM complex products, made of hard-to-handle materials. Methods. Experimental studies are carried out according to the method of the classical experiment. For the experiments, an Electronica EcoCut wire-cutting EDM machine is used. The experiments are carried out in the middle processing mode: pulse turn-on time Ton = 10 μs, pulse fill factor Tau = 30 %, average voltage U = 75 V. The electrode tool is a brass wire having a diameter of 0.25 mm. The working fluid is distilled water. Results and Discussion. Theoretical and regression models are obtained for calculating the cutting width during EDM products made of hard-to-handle materials. The dependence of the parameter on the processing conditions and the physicomechanical properties of the material is shown. It is found that with varying fill factor Tau, the response function changes according to the quadratic dependence. The maximum value of the cutting width B = 350 μm is achieved at Tau = 40 %, Ton = 15 μs. A work program is written, which gives opportunity to calculate the value of the cut width, as well as the amount of correction introduced into the work program to complete a suitable size. The accuracy of manufacturing the “stator margin plate” part is ensured. This technology is introduced in the production of oil-producing equipment.
Shlykov Evgenii
Ablyaz Timur
Muratov Karim
1. Panner Selvam M., Ranjith Kumar P. Optimization kerf width and surface roughness in wirecut electrical discharge machining using brass wire. Mechanics and Mechanical Engineering, 2017, vol. 21, no. 1, pp. 37–55.
2. Anandakumar P.A., Molla B., Biruke F., Aravind S. Analysis of copper mixed kerosene servotherm in EDM of Monel 400. IOP Conference Series: Materials Science and Engineering, 2017, vol. 197, p. 012004. DOI: 10.1088/1757-899X/197/1/012004.
3. Che Nor C.M.H., Kasim M., Mohamad E., Ito T., Sulaiman M. Study on cutting parameter on kerf width using wire electrical discharge machining of Inconel 718. 24th Design Engineering Systems Division JSME Conference Japan Society of Mechanical Engineers, Tokushima, Japan, 2014, vol. 14–27. DOI: 10.13140/2.1.1814.7844.
4. Maher I., Ling L.H., Sarhan A.D., Hamdi M. Improve wire EDM performance at different machining parameters – ANFIS modeling. IFAC-PapersOnLine, 2015, vol. 48, iss. 1, pp. 105–110. DOI: 10.1016/j.ifacol.2015.05.109.
5. Rouniyar A.K., Shandilya P. Study on powder mixed elecrtical discharge machining process: a review. DAAAM International Scientific Book, Vienna, Austria, 2019, ch. 10, pp. 123–142. DOI: 10.2507/daaam.scibook.2019.10.
6. Hayakawa S., Sasaki Y., Itoigawa F., Nakamura T. Relationship between occurrence of material removal and bubble expansion in electrical discharge machining. Procedia CIRP, 2013, vol. 6, pp. 174–179. DOI: 10.1016/j.procir.2013.03.095.
7. Chowdhury A.G.K., Ali M.Y., Banu A. Analysis of corner radius in dry micro WEDM. International Journal of Mechanical Engineering and Robotics Research, 2020, vol. 9, no 2, DOI: 10.18178/ijmerr.9.1.158–162.
8. Özerkan H.B. Simultaneous machining and surface alloying of AISI 1040 steel by electrical discharge machining with boron oxide powders. Journal of Mechanical Science and Technology, 2018, vol. 32 (9), pp. 4357–4364. DOI: 10.1007/s12206-018-0834-0.
9. Kinoshita N., Fukui M., Kimura Y. Study on wire-EDM: inprocess measurement of mechanical behaviour of electrode-wire. CIRP Annals – Manufacturing Technology, 1984, vol. 33, no. 1, pp. 89–92. DOI: 10.1016/S0007-8506(07)61386-9.
10. Dauw D.F., Sthioul H., Delpretti R., Tricarico C. Wire analysis and control for precision EDM cutting. CIRP Annals – Manufacturing Technology, 1989, vol. 38, no. 1, pp. 191–194. DOI: 10.1016/S0007-8506(07)62682-1.
11. Dey S., Roy D.C. Experimental study using different tools. International Journal of Modern Engineering Research (IJMER), 2013, vol. 3, iss. 3, pp. 1263–1267.
12. Weingärtner E., Kuster F., Wegener K. Modeling and simulation of electrical discharge machining. Procedia CIRP, 2012, vol. 2, pp. 74–78. DOI: 10.1016/j.procir.2012.05.043.
13. Abbas N.M., Solomon D.G., Bahari Md F. A review on current research trends in electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture, 2007, vol. 47, pp. 1214–1228. DOI: 10.1016/j.ijmachtools.2006.08.026.
14. Yeo S.H., Kurnia W., Tan P.C. Electro-thermal modelling of anode and cathode in micro-EDM. Journal of Physics D: Applied Physics, 2007, vol. 40 (8), pp. 2513–2521. DOI: 10.1088/0022-3727/40/8/015.
15. Yamada H., Mohri N., Furutani K., Saito N., Magara T. Transient response of wire vibration system in wire electrical discharge machining. Journal of the Japan Society for Precision Engineering, 1997, vol. 63, iss. 11, pp. 1548–1552. DOI: 10.2493/jjspe.63.1548.
16. Shlykov E.S. Povyshenie effektivnosti elektroerozionnoi obrabotki izdelii iz stalei s vysokotemperaturnoi iznosostoikost'yu. Diss. kand. tehn. nauk [Improving the efficiency of electrical discharge machining of steel products with high temperature wear resistance. PhD eng. sci. diss.]. Perm, 2018. 127 p.
17. Enache S., Opran C. Dynamic stability of the technological machining system in EDM. CIRP Annals – Manufacturing Technology, 1993, vol. 42 (1), pр. 209–214. DOI: 10.1016/S0007-8506(07)62427-5.
18. Yan M.-T., Lai Y.-P. Surface quality improvement of wire-EDM using a fine-finish power supply. International Journal of Machine Tools and Manufacture, 2007, vol. 47, pp. 1686–1694. DOI: 10.1016/j.ijmachtools.2007.01.006.
19. Balleys F., Piantchenko Ch. Surface integrity of materials machined by wire EDM machines. EDM Technology Transfer, 1996, vol. 4, pp. 3–6.
20. Kobayashi K. The present and future technological developments of EDM and ECM. Proceedings of the 11th International Symposium for Electromachining (ISEM-11), Lausanne, Switzerland, 1995, pp. 29–47.
21. Szczesniak S. Anti-electrolysis is pro EDM. Modern Machine Shop, 1998, vol. 70 (9), pр. 70–74.
This work was supported by the Ministry of Science and Higher Education of the Russian Federation on state assignment FSNM-2020-0028.
Shlykov E.S., Ablyaz T.R., Muratov K.R. Ensuring the accuracy of wire-cutting EDM processing of products made of hard-to-handle materials. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2020, vol. 22, no. 3, pp. 6–17. DOI: 10.17212/1994-6309-2020-22.3-6-17. (In Russian).
