The Effects of Using Brass and Copper Wires on the Cutting Quality of Sleipner Cold Work Steel Cut by WEDM

Year 2022, Volume: 3 Issue: 2, 163 - 178, 18.12.2022

Ferhat Ceritbinmez , Erdoğan Kanca

https://doi.org/10.55546/jmm.1117441

Cited By: 1

Abstract

Wire electric discharge machining (WEDM) is widely used in dies, punches, aerospace and automotive sectors, since materials with high hardness, and temperature resistant, which are not possible to be cut with conventional machining methods, can be cut with high precision using the WEDM method. In this study, cutting speed (mm/min), material removal rate (mm3/min), wire consume (g), machining time (sec), finish measure (mm) and surface roughness (µm) changes as a result of cutting high hardness cold work tool steel using copper and brass wire in WEDM method were investigated. In addition, worn wire and workpiece residues on the machined surfaces were detected by SEM (Scanning Electron Microscope) and EDX (Energy Dispersive X-Ray) analyzes as well as topography and composition were examined. In the case of using copper wire instead of the brass wire, wire consumption and processing time decreased by 23.30 % and 66.29 %, respectively, while MRR increased by 50 % because the copper wire electrode has higher electrical and thermal conductivity than brass wire electrode. In addition, the average dimensional deviation of the parts cut with copper wire decreased from 27 μm to 8 μm compared to the use of brass electrodes, and more precise measurements were obtained.

Keywords

WEDM, Stell, Wear, Surface Roughness, Material Removal Rate

Thanks

We would like to thank the Haier Europe, Candy-Hoover tool shop employees who supported the operation of the Charmilles Robofil 290P WEDM machine used in this study.

WEDM ile Kesilen Sleipner Soğuk İş Çeliğinin Kesim Kalitesine Pirinç ve Bakır Tel Kullanımının Etkileri

Abstract

Geleneksel işleme yöntemleriyle kesilmesi mümkün olmayan yüksek sertlik ve sıcaklığa dayanıklı malzemeler tel elektrik deşarjlı işleme (WEDM) yönteminde yüksek hassasiyetle kesilebildiğinden; bu yöntem kalıp, zımba, havacılık ve otomotiv sektörlerinde yaygın olarak kullanılmaktadır. Bu çalışmada, yüksek sertliğe sahip soğuk iş takım çeliğinin WEDM yönteminde bakır ve pirinç teller ile kesilmesi neticesinde elde edilen kesme hızı (mm/dak), talaş kaldırma oranı (mm3/dak), tel tüketimi (g), işleme zamanı (sn), bitiş ölçüsü (mm), yüzey pürüzlüğü (µm) değişimi incelenmiştir. Ayrıca SEM (Taramalı Elektron Mikroskobu) ve EDX (Energy Dispersive X-Ray) analizleri ile işlenen yüzeylerde aşınmış tel ve iş parçası kalıntıları tespit edilerek topografya ve kompozisyon incelenmiştir. Pirinç tel yerine bakır tel kullanılması durumunda tel tüketimi ve işlem süresi sırasıyla % 23.30 ve % 66.29 azalırken, bakır tel elektrot pirinç tel elektrota göre daha yüksek elektriksel ve ısıl iletkenliğe sahip olduğundan talaş kaldırma oranı % 50 artmıştır. Ayrıca bakır tel ile kesilen parçaların ortalama ölçüsel sapması pirinç elektrot kullanımına göre 27 μm'den 8 μm'ye düşmüş ve daha yüksek ölçüsel hassasiyet elde edilmiştir.

Keywords

Çelik, Aşınma, Yüzey Pürüzlüğü, Talaş Kaldırma Oranı, WEDM

References

• Aldas K., Özkul İ., Akkurt A., An ANFIS-based approach for predicting the surface roughness of cold work tool steel in WEDM. TEM Journal 2(3), 234-240, 2013.
• Alias A., Abdullah B., Abbas N. M., WEDM: Influence of machine feed rate in machining titanium Ti-6Al-4 V using brass wire and constant current (4A). Procedia Engineering 41, 1812-1817, 2012.
• Biswas M. S., Mandal K., Sarkar S., MOGA approach in WEDM of advanced aluminium alloy. Materials Today: Proceedings 26(2), 887-890, 2020.
• Ceritbinmez F., An investigation on cutting of the cold work steel X153CrMoV12 by WEDM. Aircraft Engineering and Aerospace Technology 93(10), 1674-1680, 2021.
• Chaudhary T., Siddiquee A. N., Chanda A. K., Effect of wire tension on different output responses during wire electric discharge machining on AISI 304 stainless steel. Defence Technology 15(4), 541-544, 2019.
• Çetin M., Günen A., Kalkandelen M., Karakaş M. S., Microstructural, wear and corrosion characteristics of boronized AISI 904L super austenitic stainless steel. Vacuum 187, 110145, 2021.
• Deshmukh S. S., Zubair A. S., Jadhav V. S., Shrivastava R., Optimization of process parameters of wire electric discharge machining on AISI 4140 using Taguchi method and Grey relational analysis. Materials Today: Proceedings 18, 4261-4270, 2019.
• Gaitonde V. N., Manjaiah M., Maradi S., Karnik S. R., Petkar P. M., Davim J. P., Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE). In Computational methods and production engineering. Woodhead Publishing, pp. 199-221, 2017.
• Gökler M. İ., Ozanözgü A. M., Experimental investigation of effects of cutting parameters on surface roughness in the WEDM process. International Journal of Machine Tools and Manufacture 40(13), 1831-1848, 2000.
• Günen A., Ceritbinmez F., Patel K., Akhtar M. A. Mukherjee S., Kanca E., Karakas M. S., WEDM machining of MoNbTaTiZr refractory high entropy alloy. CIRP Journal of Manufacturing Science and Technology 38, 547-559, 2022.
• Kirkhorn L., Frogner K., Andersson M., Ståhl J. E., Improved tribotesting for sheet metal forming. Procedia CIRP 3, 507-512, 2012.
• Kumar A., Kumar V., Kumar J., A review on the state of the art in wire electric discharge machining (WEDM) process. International Journal of Mechanical Engineering Research and Development (IJMERD) 1(1), 23-29, 2011.
• Lodhi B. K., Agarwal S., Optimization of machining parameters in WEDM of AISI D3 Steel using Taguchi Technique. Procedia CIRP 14, 194-199, 2014.
• Lodhi B. K., Agarwal S., Ahamad S., Optimization of WEDM parameters on surface roughness of EN41B steel. Materials Today: Proceedings 25, 816-820, 2020.
• Magabe R., Sharma N., Gupta K., Davim J. P., Modeling and optimization of Wire-EDM parameters for machining of Ni 55.8 Ti shape memory alloy using hybrid approach of Taguchi and NSGA-II. The International Journal of Advanced Manufacturing Technology 102(5), 1703-1717, 2019.
• Mandaloi G., Singh S., Kumar P., Pal K., Effect on crystalline structure of AISI M2 steel using tungsten–thorium electrode through MRR, EWR, and surface finish. Measurement 90, 74-84, 2016.
• Mukhopadhyay A., Barman T. K., Sahoo P., Davim J. P., Modeling and optimization of fractal dimension in wire electrical discharge machining of EN 31 steel using the ANN-GA approach. Materials 12(3), 454, 2019.
• Nalbant M., Gökkaya H., Sur G., Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning. Materials & Design 28(4), 1379-1385, 2007.
• Ozkul I., Buldum B. B., Akkurt A., Machinabilty of Sleipner cold work steel with wire electro discharge machining. International Journal of Electronics, Mechanical and Mechatronics Engineering (IJEMME) 2(3), 252-260, 2013.
• Pantazopoulos G., Psyllaki P., Kanakis D., Antoniou S., Papadimitriou K., Sideris J., Tribological properties of a liquid nitrocarburised special purpose cold work tool steel. Surface and Coatings Technology 200(20-21), 5889-5895, 2006.
• Patnaik P., Datta S., Mahapatra S. S., WEDM Performance of Ti-6Al-4V: Emphasis on Multi-Cut Strategy, Effects of Electrode Wire. Materials Today: Proceedings 18, 4102-4110, 2019.
• Ramaswamy A., Perumal A. V., Jagadeesan J., Nagarajan H. V., Optimization of WEDM process parameters for D3 die steel using RSM. Materials Today: Proceedings 37, 2063-2069, 2021.
• Rao K. V., Raju L. R., Kumar C. K., Modeling of kerf width and surface roughness in wire cut electric discharge machining of Ti-6Al-4V. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 234(6), 533-542, 2020.
• Reolon L. W., Laurindo C. A. H., Torres R. D., Amorim F. L., WEDM performance and surface integrity of Inconel alloy IN718 with coated and uncoated wires. The International Journal of Advanced Manufacturing Technology 100(5), 1981-1991, 2019.
• Sangwan K.S., Saxena S., Kant G., Optimization of machining parameters to minimize surface roughness using integrated ANN-GA approach. Procedia Cirp 29, 305-310, 2015.
• Sudhakara D., Prasanthi G., Application of Taguchi method for determining optimum surface roughness in wire electric discharge machining of P/M cold worked tool steel (Vanadis-4E). Procedia Engineering 97, 1565-1576, 2014.
• Straka Ľ., Piteľ J., Čorný I., Influence of the main technological parameters and material properties of the workpiece on the geometrical accuracy of the machined surface at wedm. The International Journal of Advanced Manufacturing Technology 115, 3065-3087, 2021.
• Wang Y., Wu C. Z., Chai H. Y., Xiong W., Wang R., Yang J., Study on surface characteristics in ultrasonic vibration-assisted WEDM-LS based on spatial vibration of electrode wire. The International Journal of Advanced Manufacturing Technology 114(9), 2677-2695, 2021.
• Zhang G., Huang H., Zhang Z., Zhang Y., Study on the effect of three dimensional wire vibration on WEDM based on a novel thermophysical model. The International Journal of Advanced Manufacturing Technology 100(5), 2089-2101, 2019.