Vol. 26 No. 4 2024 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Aff airs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 26 No. 4 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Manikanta J.E., Ambhore N., Shamkuwar S., Gurajala N.K., Dakarapu S.R. Investigation of vegetable-based hybrid nanofl uids on machining performance in MQL turning........................................................................................... 6 Dama Y.B., Jogi B.F., Pawade R., Kulkarni A.P. Impact of print orientation on wear behavior in FDM printed PLA Biomaterial: Study for hip-joint implant...................................................................................................................... 19 GrinenkoA.V., ChumaevskyA.V., Sidorov E.A., Utyaganova V.R.,AmirovA.I., Kolubaev E.A. Geometry distortion, edge oxidation, structural changes and cut surface morphology of 100mm thick sheet product made of aluminum, copper and titanium alloys during reverse polarity plasma cutting...................................................................................... 41 Somatkar A., Dwivedi R., Chinchanikar S. Comparative evaluation of roller burnishing of Al6061-T6 alloy under dry and nanofl uid minimum quantity lubrication conditions............................................................................................... 57 Karlina Yu.I., Konyukhov V.Yu., Oparina T.A. Assessment of the quality and mechanical properties of metal layers from low-carbon steel obtained by the WAAM method with the use of additional using additional mechanical and ultrasonic processing..................................................................................................................................................... 75 EQUIPMENT. INSTRUMENTS Yusubov N.D., Abbasova H.M. Systematics of multi-tool setup on lathe group machines............................................... 92 Toshov J.B., Fozilov D.M., Yelemessov K.K., Ruziev U.N., Abdullayev D.N., Baskanbayeva D.D., Bekirova L.R. Increasing the durability of drill bit teeth by changing its manufacturing technology......................................................... 112 Pospelov I.D. Investigation of the distribution of normal contact stresses in deformation zone during hot rolling of strips made of structural low-alloy steels to increase the resistance of working rolls..................................................... 125 Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method.......................... 138 MATERIAL SCIENCE Shubert A.V., Konovalov S.V., Panchenko I.A. A review of research on high-entropy alloys, its properties, methods of creation and application.................................................................................................................................................. 153 Syusyuka E.N., Amineva E.H., Kabirov Yu.V., Prutsakova N.V. Analysis of changes in the microstructure of compression rings of an auxiliary marine engine.......................................................................................................... 180 Dudareva A.A., Bushueva E.G., Tyurin A.G., Domarov E.V., Nasennik I.E., Shikalov V.S., Skorokhod K.A., Legkodymov A.A. The eff ect of hot plastic deformation on the structure and properties of surface-modifi ed layers after non-vacuum electron beam surfacing of a powder mixture of composition 10Cr-30B on steel 0.12 C-18 Cr-9 Ni-Ti............................................................................................................................................................................. 192 Boltrushevich A.E., Martyushev N.V., Kozlov V.N., Kuznetsova Yu.S. Structure of Inconel 625 alloy blanks obtained by electric arc surfacing and electron beam surfacing........................................................................................... 206 Sablina T.Y., Panchenko M.Yu., Zyatikov I.A., Puchikin A.V., Konovalov I.N., Panchenko Yu.N. Study of surface hydrophilicity of metallic materials modifi ed by ultraviolet laser radiation........................................................................ 218 EDITORIALMATERIALS 234 FOUNDERS MATERIALS 243 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method Timur Ablyaz a, Vladimir Blokhin b, Evgeniy Shlykov c, *, Karim Muratov d, Ilya Osinnikov e Perm National Research Polytechnic University, 29 Komsomolsky prospekt, Perm, 614990, Russian Federation a https://orcid.org/0000-0001-6607-4692, lowrider11-13-11@mail.ru; b https://orcid.org/0009-0009-2693-6580, warkk98@mail.ru; c https://orcid.org/0000-0001-8076-0509, Kruspert@mail.ru; d https://orcid.org/0000-0001-7612-8025, Karimur_80@mail.ru; e https://orcid.org/0009-0006-4478-3803, ilyuhaosinnikov@bk.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. 2024 vol. 26 no. 4 pp. 138–152 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.4-138-152 ART I CLE I NFO Article history: Received: 13 September 2024 Revised: 08 October 2024 Accepted: 17 October 2024 Available online: 15 December 2024 Keywords: Rapid prototyping method Master model Precision Stereolithography Liquid photopolymer Copy-and-pierce electrical discharge machining Flatness deviation Funding The research was fi nancially supported by the Russian Science Foundation grant No. 23-79-01224, https://rscf.ru/ project/23-79-01224/. Acknowledgements The authors express their gratitude to Associate Professor of the department. ITM Federal Autonomous Educational Institution of Higher Education “Perm National Research Polytechnic University” Shumkov A.A. for assistance in obtaining and designing master models by the rapid prototyping method. ABSTRACT Introduction. This paper presents the results of obtaining a complex-profi le tool electrode (TE) for copy-and-pierce electrical discharge machining by casting technology. This method consists in using a master model by rapid prototyping method. The purpose of the work: experimental study of accuracy assurance in manufacturing of complex-profi le TE by casting with the use of rapid prototyping technology for copypiercing electrical discharge machining. Research Methods. The master model of TE was produced on the Envisiontec Perfactory XEDE machine using stereolithography technology. Si500 photopolymer was used as a starting material. Intermediate and fi nal surface deviation measurements were performed on a Contura Carl Zeiss G2 CMM. Calculation of the gutter and feed system was performed in ProCast software. A casting was obtained from casting brass LC40S (Cu-40 Zn-Pb). The study of the process of copy-piercing electrical discharge machining of TE made by casting with the use of rapid prototyping technology was carried out with the help of Smart CNC copy-piercing machine in the environment of transformer oil. Operating parameters: pulse turn-on time (Ton, μs), voltage (U, V), current (I, A). Results and discussion. The methodology of design and manufacturing of complex-profi le TE with application of rapid prototyping technology for copypiercing electrical discharge machining is developed. The analysis of shape deviation shows that errors occur during the manufacturing of the master model by stereolithography. An experimental study of the shape deviation of the master model shows surface concavity in the range of 0.03 to 0.07 mm depending on the arrangement of the sides. It is shown that the optimized master model has 25 % less shape deviation. A sprue-feeding system (SFS) is developed for the fabrication of TE by casting technology. When porosity is evaluated, it is found that pores are concentrated in the SFS and riser, which positively aff ects the quality of the casting. Manufacturing of the tool electrode with the help of casting technology showed that all accuracy and roughness parameters are within the specifi ed tolerance and correspond to the initial drawing data. Experimental study of the process of electroerosion machining of the profi le groove of the TE manufactured by casting on the investment casting model obtained with the use of rapid prototyping technology is carried out. It is established that the dimensions of the obtained groove meet the stated requirements. For citation: Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 4, pp. 138–152. DOI: 10.17212/1994-6309-2024-26.4-138-152. (In Russian). ______ * Corresponding author Shlykov Evgeniy S., Ph.D. (Engineering), Associate Professor Perm National Research Polytechnic University, 29 Komsomolsky prospect, 614990, Perm, Russian Federation Tel.: +7 961 759-88-49, e-mail: Kruspert@mail.ru
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Introduction Machining is used to produce complex profi le surfaces. This method has a number of technological and economic disadvantages. To obtain diff erent profi les, it is necessary to manufacture diff erent profi le cutting tools that are applicable in one technological transition. Under such conditions, the production cycle of the product increases due to frequent tool changes. When providing the required surface profi le, it is mainly required to use equipment with the possibility of multi-axis machining, which leads to an increase in the cost of the product [1–3]. Copy-piercing electrical discharge machining (CPEDM) is widely used to produce complex profi le surfaces. CPEDM allows obtaining the profi le of products of various shapes with minimal expenditures on tools and tooling. Technological transitions do not require the use of special tooling due to the absence of cutting forces in the process of CPEDM [4–7]. The effi ciency of CPEDM depends on the quality of the tool electrode (TE). In modern production, complex profi le EDMs are produced by machining methods (turning, milling). The required surface contour often makes demand for TE that cannot be produced by three-axis machining and then TE is produced on fi ve-axis machining centers with the use of special tooling and cutting tools. These methods of TE manufacturing require signifi cant economic and time expenditures. It is not reasonable to use it within the framework of mass production. For pilot production it is characteristic to produce one test sample for making subsequent changes in its design to minimize the production cycle to ensure the required result. A relevant solution is the production of complex-profi le TE using investment casting technology with obtaining a master model using the rapid prototyping method. The rapid prototyping technology allows producing a prototype of TE to assess the quality and quickly correct the product model. The use of additive technologies to obtain a master model makes it possible to manufacture single TE of diff erent profi les in a short time. Modern equipment used in additive manufacturing allows producing a batch of TE with diff erent profi les in one production cycle, which helps to reduce economic costs and shorten the production cycle [8]. Literature analysis [9–11] showed that it is possible to produce prototypes of products with minimal deviations and structural defects using the technology of rapid prototyping from liquid photopolymers. The application of this technology allows providing the required parameters of repeatable geometry of complex-profi le elements. The works [12–16] note the eff ectiveness of this technology for obtaining the required complex-profi le products. However, the issue of the accuracy of master models obtained by stereolithography has not been fully studied at present. The actual task is the development of scientifi cally substantiated approaches for manufacturing of complex-profi le ET by alternative technologies. The purpose of the work is to ensure the accuracy of manufacturing of complex-profi le TE by casting with the use of rapid prototyping technology for copy-piercing electrical discharge machining. Objectives: 1) to develop a methodology for designing and manufacturing complex-profi le TE for CPEDM using rapid prototyping technology to create a master model; 2) to analyze the shape deviations of a master model made of liquid photopolymer using a coordinate measuring machine (CMM); 3) to perform CAD model correction to reduce the shape deviation of the master model; 4) to develop a sprue-feeding system and evaluate the porosity of the casting during metal pouring; 5) to conduct an experimental study of the accuracy of the CPEDM process of the profi le groove of the TE made by casting with obtaining the investment pattern using the rapid prototyping technology. Research methodology The experiments were conducted on the basis of the Center for Collective Usage of the Department of “Innovative technologies of mechanical engineering” of the Federal Autonomous Educational Institution of Higher Education “Perm National Research Polytechnic University”. Within the framework of the research
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 5 samples of tool-electrodes for CPEDM of a blind profi le groove in special-purpose products were produced using investment casting method; a sketch of the TE is presented in Fig. 1. The tool-electrodes were designed taking into account the inter-electrode gap (IEG) calculated according to the methodology presented in [17, 18]. CAD-model with sprue-feeding system was designed in SOLIDWORKS computer-aided design system. Processing of the CAD-model for the production of investment pattern by stereolithography (SLA) method was carried out using the Materialles Magics software package. The design of supports (Fig. 2) is necessary for free removal from the working place of construction. To minimize cost of SLA production, the internal fi lling of the TE was performed with a cellular structure of a Wigner – Seitz face-centered cubic lattice (Fig. 2). This type of lattice holds equiaxial loading well, which allows obtaining a master model with acceptable shape deviations after post-polymerization of the material in air [19–21]. Fig. 1. Sketch of the tool electrode Fig. 2. Supports for TE Growing of TE was carried out on a mask-type Envisiontec Perfactory XEDE unit. The mode parameters are presented in Table 1. The patterns were manufactured using a photopolymer material based on acrylates (Si500), which belongs to the class of cross-linked polymers. The characteristics of the material under normal conditions are presented in Table 2. The CAD model of the TE prototype with a sprue-feeding system (SFS) is shown in Fig. 3. The ProCast software package was used to calculate the SFS. When designing the SFS, it is necessary to take into account the following: 1) identical conditions for each section of the casting during casting; 2) for thick-walled sections, the presence of an additional depot of liquid metal in order to eliminate defects (shrinkage cavities, weakness and porosity in the metal); Ta b l e 1 Parameters of the build mode of the investment pattern by SLA method Parameter Value Layer thickness, μm 50 Supports height, mm 3 Thickness of supports, μm 280 Time of illumination of model section and supports, ms 8,500
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Ta b l e 2 Characteristics of Si500 photopolymer material under normal conditions Parameter Value Tensile modulus of elasticity (E), MPa 2.68 Ultimate strength (σ), MPa 78.1 Relative strain (ɛ), % 4.39 Bending strength (σ), MPa 65 Glass transition temperature (T), °C 61 Density in liquid state (ρ), g/cm3 1.1 Density in solid state (ρ), g/cm3 1.2 Fig. 3. TE model with sprue-feeding system 3) the direction of hot metal from thick-walled sections to thin-walled ones. After the master model was made for each TE, a model kit of SFS and a casting model from casting wax were formed using a silicone mold. The obtained wax models of the electrodes were connected with SFS. The wax TEs with SFS were then mounted in a mold and fi lled with gypsum. The mold was calcined to a temperature of 750 °C. After the mold cooled down to a temperature of 450 °C, the models were calcined in an induction crucible furnace, and then the castings were removed from the mold. The material used was foundry brass Cu-40 Zn-Pb. Master models as well as wax models and subsequent castings were measured on a Contura Carl Zeiss G2 three-axis CMM. Shape deviations and the magnitude of possible corrections were considered. The samples under study were mounted perpendicular to the plane of the table, and the displacements relative to the cross-section of the vertical and horizontal surfaces of the prototype were measured. Four surfaces were measured on each obtained TE. The measured surfaces and the measurement strategy are shown in Fig. 4. a b Fig. 4. Measured surfaces of the tool electrodes (a) and the trajectory of measuring the TE (b)
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 The measurement strategy is a polyline. The measurement was performed in such a way as to maximize the use of the entire surface. As a result, statistics from 200 points in three x, y, z coordinates were collected. To test the obtained metallic TE, an experiment was conducted on CPEDM of steel 45 (0.45 % C). The processing was performed on a CPEDM Smart CNC machine in the environment of industrial oil grade I-20a GOST 982-80. The CPEDM mode is presented in Table 3. Ta b l e 3 Machining mode on the copy-piercing EDM machine Parameters Values max I, А 8 U, V 50 Ton, μs 100 Results and discussion Fig. 5 shows the cellular structure of the internal fi lling of the investment patterns. Fig. 5. Cell fi lling with the structure of a face-centered Wigner-Seitz cubic lattice The Calypso software package shows the average fl atness deviations on surfaces 1–4 (Fig. 6) of all fi ve TE samples. The approximation method was used to model the fl atness deviation error line. A data sampling of twelve points for each plane was made for visualization. The points were selected on the measurement line where it breaks. The sampling data for surface 1 is presented in Table 4. The location of these points is shown in Fig. 7. An approximation line is drawn through these points, indicating the average actual size of the master models. Table 5 shows the fl atness deviations of the samples of all measured surfaces and the average value. It is necessary to take these deviations into account and add it to the original CAD model to create a new geometry of the part. To eliminate the resulting deviation, a new dimension is calculated that compensates for the shape deviation and is equal to the average size of the fl atness deviation. Fig. 8 shows the changes in the part shape geometry on surfaces 1–4.
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 a b c d Fig. 6. Measurement trajectory with the value of average fl atness deviation along the surface: a – 1; b – 2; c – 3; d – 4 Ta b l e 4 Sampling points from surface 1 Surface Point Coordinates of points on the surface 1 Х Y Z 1 1 264.2598 −513.1588 −477.3192 2 264.2567 −518.4794 −477.3239 3 259.5628 −517.3288 −477.2899 4 259.5518 −521.9996 −477.2986 5 255.7281 −520.0690 −477.2837 6 255.7163 −525.1954 −477.2634 7 250.7091 −523.9416 −477.2420 8 250.6929 −529.7544 −477.2196 9 244.3490 −528.7445 −477.1874 10 244.3337 −534.6175 −477.1713 11 237.7511 −536.6551 −477.1053 12 267.6178 −513.1320 −477.3031
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 Surface Point Coordinates of points on the surface 1 Х Y Z 2 1 266.8592 −536.3874 −477.330 2 266.8582 −539.1545 −477.2888 3 262.9658 −539.3621 −477.3156 4 258.9135 −542.0315 −477.2840 5 254.9696 −539.4720 −477.2727 6 250.3227 −541.9105 −477.2169 7 245.5120 −543.7889 −477.1600 8 237.8660 −544.3309 −477.1061 9 230.9308 −544.0254 −477.0633 10 227.6826 −544.4671 −477.0632 11 234.7477 −544.6761 −477.0746 12 236.7347 −543.6066 −477.0987 3 1 268.8741 −517.3798 −479.1381 2 268.7148 −517.5176 −488.4096 3 266.4900 −519.2954 −481.6966 4 266.5182 −519.2315 −489.1544 5 262.5285 −522.4333 −481.4241 6 262.0909 −522.7745 −489.2207 7 259.3579 −524.9424 −484.7519 8 258.9885 −525.2224 −489.5129 9 252.9817 −529.9868 −481.4362 10 254.9560 −528.4201 −48.5392 11 249.1152 −533.0230 −482.6272 12 242.8281 −538.0595 −489.9179 4 1 264.0658 −510.4802 −481.0604 2 263.1891 −511.1592 −490.5512 3 260.0128 −513.6948 −481.1179 4 258.2810 −515.0385 −488.8638 5 253.7875 −518.5229 −482.0872 6 253.1226 −519.1440 −490.6190 7 249.1201 −522.2798 −481.9732 8 249.2972 −522.1993 −491.0848 9 245.1400 −525.4132 −481.5228 10 242.5907 −527.4970 −491.0312 11 237.5517 −531.5133 −490.5426 12 236.7127 −532.0627 −481.5488 T h e E n d Ta b l e 4
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 a b c d Fig. 7. Average fl atness deviation on the surface: a – 1; b – 2; c – 3; d – 4 Ta b l e 5 Flatness deviation (mm) Sample No. Surfaces 1 2 3 4 1 0.0517 0.0512 0.0715 0.0346 2 0.0528 0.0519 0.0717 0.0341 3 0.0523 0.0519 0.0720 0.0352 4 0.0521 0.0529 0.0710 0.0351 5 0.0521 0.0530 0.0724 0.0351 Average value 0.0522 0.0522 0.0718 0.0348 a b c d Fig. 8. Assumed geometry of the shape on the surface: a – 1; b – 2; c – 3; d – 4
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 The calculated nominal dimensions are added into the CAD model (Fig. 9), and a new geometry of surfaces 1–4 is created. After the changes weremade, themaster models were re-grown on the original mode. Master models were grown vertically. Supports were located on the non-working part of the electrode. Repeated measurements of fl atness deviations of all surfaces of the master models were performed. Table 6 shows the repeated measurements of the TE models. Ta b l e 6 Measurements of TE models after re-build TE No. Surfaces 1 2 3 4 1 0.0388 0.0400 0.0539 0.0301 2 0.0394 0.0382 0.0549 0.0305 3 0.0394 0.0395 0.0538 0.0309 4 0.0397 0.0399 0.0530 0.0311 5 0.0387 0.0385 0.0538 0.0314 Average value 0.0392 0.0392 0.0539 0.0308 Fig. 9. Modifi ed geometry of the mold taking into account the performed calculations on the surface: a – 1; b – 2; c – 3; d – 4 а b c d
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Fig. 10. Porosity distribution in the body of the part casting The analysis of the obtained data shows a decrease in the average deviation of master model growth by 25 % of the fi rst, second and third surfaces. The fl atness deviation of surface 4 decreased by 11.5 % due to the smaller surface area and the smaller angle of its location relative to the table. When making a casting, the mold was fi lled with melt through a slot feeder. As the melt entered the thin areas of the casting, the cooling rate was equalized and gas was removed from the casting. This ensures that there are no shrinkage pores in the body of the TE casting. The distribution of pores in feed and sprue system calculated in the ProCast software is shown in Fig. 10. The entire model has about 13 % porosity. It is found that the defect does not aff ect the critical part of the casting of the part. This fact improves the surface quality and density of the metal. The program performs calculations under ideal conditions. Actual results may diff er from the calculations. Based on the calculation performed, the correctness of the designed casting and SFS is proved. Fig. 11, a shows the master model after correction; the wax model is shown in Fig. 11, b. Fig. 11, c shows the metal casting with SFS, which is separated from the part by a cutoff tool. Metal TE with the fi xing method and the corresponding groove profi le machined by copy-piercing electrical discharge machining method with the obtained metal TE are presented in Figs. 11, g–f. During the experiment, a master model, a wax model, and a metal casting were obtained. Table 7 shows the specifi ed dimensions and roughness of the CAD model and the data obtained by measuring the metal casting. The obtained dimensions and roughness of the metal casting satisfy the specifi ed parameters. According to the results of the experimental study of the use of TE, manufactured using the casting technology with the use of rapid prototyping method to obtain a master model, the surface quality of the profi le groove meets the requirements of the drawing. The taken into account interelectrode gap (IEG) allows for dimensions within the 12th accuracy degree, which meets the requirements of pilot production. Conclusions 1. A methodology for designing and manufacturing a complex-shaped TE using rapid prototyping technology for copy-piercing electrical discharge machining is developed.
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 6 4 4 а b c d e f Fig. 11. Technological process of TE manufacturing: a – master model; b – wax model; c – metal casting with SFS; d – TE; e – TE with fi xing; f – mating profi le of groove surface after CPEDM Ta b l e 7 Comparative table of measurement results Dimensions (mm) Roughness (μm) Sides 1–2 Sides 3–4 Sides 1–2 Sides 3–4 CAD model 29-0.13 8-0.09 Ra 1.6 Ra 1.6 Metal casting 28.90 7.98 Ra 1.6 Ra 1.6 2. Analysis of shape deviations has shown that errors occur when manufacturing a master model using stereolithography. 3. An experimental study of the shape deviation of the master model has shown a surface concavity in the range from 0.03 to 0.07 mm depending on the location of the sides. 4. It is shown that the optimized master model has 25 % fewer shape deviations.
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