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Study on removal of recast layer of NiTi shape memory alloy machined with magnetic field-assisted WEDM-ECM complex process

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Abstract

In this paper, a magnetic field-assisted WEDM-ECM complex process (MF-assisted WEDM-ECM) is proposed to solve the problems of traditional low-speed wire electrical discharge machining (WEDM-LS) of NiTi SMA, including low machining efficiency, high workpiece surface roughness, and large recast layer thickness. Electrolytic machining is used to remove the recast layer, and magnetic field-assisted method is used to reduce the surface roughness and improve the machining efficiency. Firstly, based on the double-layer model the removal thickness of recast layer is deduced, and the removal thickness of recast layer under different machining parameters is analyzed. In addition, based on the influence of magnetic field on discharge channel, the single spark crater analytical model is modified. Based on this model, combined with the electrochemical corrosion rate and the wire electrode vibration response equation, a continuous discharge corrosion mathematical model is established to predict the surface topography of the workpiece, and the simulation analysis is carried out. Finally, comparison of the experimental results of traditional WEDM-LS, MF-assisted WEDM-LS, ultrasonic vibration (USV)-MF complex-assisted WEDM-LS, and MF-assisted WEDM-ECM in machining NiTi SMA reveals that MF-assisted WEDM-ECM has the best machining performance. Compared with traditional WEDM-LS, the material removal rate (MRR) of MF-assisted WEDM-ECM was increased by 26.2%, the surface roughness value was reduced by 19.2%, and the thickness of recast layer was reduced by 44.25%. The average errors of the experimental and predicted values of workpiece surface roughness, recast layer removal thickness, and kerf width are 8.3%, 6.41%, and 3.58%, respectively, which verified the accuracy of the theoretical model proposed in this paper.

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Funding

The authors declare that this work was sponsored by Natural Science Foundation of Shanghai.

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Shanghai for Science and Technology, Shanghai, 200093, China

    Yan Wang, Cai-Cong Tang, Hua-Yi Chai, Yi-Zhang Chen, Rui-Qi Jin & Wei Xiong

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  1. Yan Wang
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Wang, Y., Tang, CC., Chai, HY. et al. Study on removal of recast layer of NiTi shape memory alloy machined with magnetic field-assisted WEDM-ECM complex process. Int J Adv Manuf Technol 129, 4335–4354 (2023). https://doi.org/10.1007/s00170-023-12588-3

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