Skip to main content
SpringerLink
Log in

Recast layer removal of WEDMed surface by wire electrochemical finishing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

To eliminate the recast layer on the surface machined by multi-pass wire electrical discharge machining (WEDM), hence improving the surface integrity, the present paper proposed and investigated a new combined machining process of performing wire electrochemical machining (WECM) after multi-pass WEDM on the same machine tool by utilizing the slight conductivity of the compound working fluid. A theoretical model based on the electric double layer and Faraday’s law of electrolysis was established to calculate the wire feed rate for WECM finishing. Due to the exclusive film protection of the compound working fluid, the theoretical model was modified according to the experimental results under different electrolyte concentrations. Afterward, the optimized model was applied to guide the experiments of the combined process. An electrolyte concentration of 1:5 was used to facilitate the electrochemical reaction. The experimental results showed that the remaining recast layer after multi-pass WEDM could be completely removed at a wire feed rate of 10 µm/s, and a fine surface finish could be obtained. In addition, the surface roughness of the machined part was improved from 1.458 µm Ra to 0.683 µm Ra.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Materials availability

The data and materials set supporting the results are included within the article.

References

  1. Ho K, Newman S, Rahimifard S, Allen R (2004) State of the art in wire electrical discharge machining (WEDM). Int J Mach Tools Manuf 44(12–13):1247–1259. https://doi.org/10.1016/j.ijmachtools.2004.04.017

    Article  Google Scholar 

  2. Prasad D, Krishna AG (2015) Empirical modeling and optimization of kerf and wire wear ratio in wire electrical discharge machining. Int J Adv Manuf Technol 77(1):427–441. https://doi.org/10.1007/s00170-014-6445-8

    Article  Google Scholar 

  3. Antar M, Soo S, Aspinwall D, Sage C, Cuttell M, Perez R, Winn A (2012) Fatigue response of Udimet 720 following minimum damage wire electrical discharge machining. Mater Des 42:295–300. https://doi.org/10.1016/j.matdes.2012.06.003

    Article  Google Scholar 

  4. Kumar S, Verma A (2021) Surface modification during electrical discharge machining process-a review. Mater Today: Proc 46:5228–5232. https://doi.org/10.1016/j.matpr.2020.08.596

    Article  MathSciNet  Google Scholar 

  5. Ayesta I, Izquierdo B, Flano O, Sánchez JA, Albizuri J, Aviles R (2016) Influence of the WEDM process on the fatigue behavior of Inconel® 718. Int J Fatigue 92:220–233. https://doi.org/10.1016/j.ijfatigue.2016.07.011

    Article  Google Scholar 

  6. Hou Y, Xu J, Lian Z, Pei Q, Yang S, Zhai C, Yu H (2022) Surface integrity evolution of zirconium-based metallic glass multi-cut with wire electrical discharge machining. J Mater Eng Perform 31(5):4158–4166. https://doi.org/10.1007/s11665-021-06518-1

    Article  Google Scholar 

  7. Khan SA, Usman M, Pervaiz S, Saleem MQ, Naveed R (2021) Exploring the feasibility of novel coated wires in wire EDM of Ti-6Al-4V aerospace alloy: a case of multi-pass strategy. J Braz Soc Mech Sci Eng 43(5):1–9. https://doi.org/10.1007/s40430-021-02994-7

    Article  Google Scholar 

  8. Singh MA, Sarma DK, Hanzel O, Sedláček J, Šajgalík P (2018) Surface characteristics enhancement of MWCNT alumina composites using multi-pass WEDM process. J Eur Ceram Soc 38(11):4035–4042. https://doi.org/10.1016/j.jeurceramsoc.2018.04.062

    Article  Google Scholar 

  9. Sharma V, Patel DS, Agrawal V, Jain V, Ramkumar J (2021) Investigations into machining accuracy and quality in wire electrochemical micromachining under sinusoidal and triangular voltage pulse condition. J Manuf Processes 62:348–367. https://doi.org/10.1016/j.jmapro.2020.12.010

    Article  Google Scholar 

  10. Kurita T, Hattori M (2006) A study of EDM and ECM/ECM-lapping complex machining technology. Int J Mach Tools Manuf 46(14):1804–1810. https://doi.org/10.1016/j.ijmachtools.2005.11.009

    Article  Google Scholar 

  11. Nguyen MD, Rahman M, San Wong Y (2012) Simultaneous micro-EDM and micro-ECM in low-resistivity deionized water. Int J Mach Tools Manuf 54:55–65. https://doi.org/10.1016/j.ijmachtools.2011.11.005

    Article  Google Scholar 

  12. Li L, Wei X, Li Z (2014) Surface integrity evolution and machining efficiency analysis of W-EDM of nickel-based alloy. Appl Surf Sci 313:138–143. https://doi.org/10.1016/j.apsusc.2014.05.165

    Article  Google Scholar 

  13. Mandal A, Dixit AR, Chattopadhyaya S, Paramanik A, Hloch S, Królczyk G (2017) Improvement of surface integrity of Nimonic C 263 super alloy produced by WEDM through various post-processing techniques. Int J Adv Manuf Technol 93(1):433–443. https://doi.org/10.1007/s00170-017-9993-x

    Article  Google Scholar 

  14. Han Z, Fang X, Zeng Y, Zhu D (2022) Wire electrochemical trimming the recast layer on rené 88DT for aero-engine applications. Electrochim Acta 418(140):372. https://doi.org/10.1016/j.electacta.2022.140372

    Article  Google Scholar 

  15. Wu X, Li S, Jia Z, Xin B, Yin X (2019) Using WECM to remove the recast layer and reduce the surface roughness of WEDM surface. J Mater Process Technol 268:140–148. https://doi.org/10.1016/j.jmatprotec.2019.01.016

    Article  Google Scholar 

  16. Debnath S, Kundu J, Bhattacharyya B (2018) Modeling and influence of voltage and duty ratio on wire feed in WECM: possible alternative of WEDM. J Electrochem Soc 165(2):E35. https://doi.org/10.1149/2.0601802jes

    Article  Google Scholar 

  17. Kang J, Wen J, Jayaram SH, Yu A, Wang X (2014) Development of an equivalent circuit model for electrochemical double layer capacitors (EDLCs) with distinct electrolytes. Electrochim Acta 115:587–598. https://doi.org/10.1016/j.electacta.2013.11.002

    Article  Google Scholar 

  18. Pan H, Liu Z, Li C, Zhang Y, Qiu M (2017) Enhanced debris expelling in high-speed wire electrical discharge machining. Int J Adv Manuf Technol 93(5):2913–2920. https://doi.org/10.1007/s00170-017-0716-0

    Article  Google Scholar 

  19. Zhang M, Zhidong L, Hongwei P, Cong D, Mingbo Q (2021) Effect of no-load rate on recast layer cutting by ultra fine wire-EDM. Chin J Aeronaut 34(4):124–131. https://doi.org/10.1016/j.cja.2020.08.007

    Article  Google Scholar 

  20. Pramanik A, Basak A, Prakash C, Shankar S, Sharma S, Narendranath S (2021) Recast layer formation during wire electrical discharge machining of Titanium (Ti-Al6-V4) alloy. J Mater Eng Perform 30(12):8926–8935. https://doi.org/10.1007/s11665-021-06116-1

    Article  Google Scholar 

Download references

Acknowledgements

The authors extend their sincere thanks to those who contributed in the preparation of the instructions.

Funding

This work was supported by the National Natural Science Foundation of China (grant number 51975290).

Author information

Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, No.29, Yudao Str., Nanjing, 210016, Jiangsu, China

    Hongwei Pan, Zhidong Liu, Xinsong Chen & Xiyuan Yin

Authors
  1. Hongwei Pan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhidong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xinsong Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xiyuan Yin
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors have been personally and actively involved in substantive work leading to the report.

Corresponding author

Correspondence to Zhidong Liu.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Pan, H., Liu, Z., Chen, X. et al. Recast layer removal of WEDMed surface by wire electrochemical finishing. Int J Adv Manuf Technol 123, 2593–2604 (2022). https://doi.org/10.1007/s00170-022-10238-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10238-8

Keywords

Search

Navigation