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Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement

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Abstract

The contour method of residual stress measurement relies on the careful application of wire electro-discharge machining (WEDM) for the cutting stage. Changes in material removal rates during the cut lead to errors in the final calculated values of residual stress. In this study, WEDM cutting parameters have been explored to identify the optimum conditions for contour method residual stress measurements. The influence of machine parameters on the surface roughness and cutting artifacts in the contour cut is discussed. It has been identified that the critical parameter in improving the surface finish is the spark pulse duration. A typical cutting artifact and its impact on measured stress values have been identified and demonstrated for a contour cut in a welded marine steel. A procedure is presented to correct contour displacement data from the influence of WEDM cutting artifacts, and is demonstrated on the correction of a measured weld residual stress. The corrected contour method improved the residual stress magnitude up to 150 MPa. The corrected contour method results were validated by X-ray diffraction, incremental center hole drilling, and neutron diffraction.

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Acknowledgments

We wish to thank to Peter Ledgard and Damien Flack at The Open University for performing the EDM cutting. The authors are grateful for funding from the Lloyd’s Register Foundation, a charitable foundation helping to protect life and property by supporting engineering-related education, public engagement, and the application of research.

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Authors and Affiliations

  1. Department of Engineering and Innovation, The Open University, Walton Hall, Milton Keynes, MK7 6AA, U.K.

    Bilal Ahmad (Research Associate) & Michael E. Fitzpatrick (Professor, Lloyd´s Register Foundation Chair in Structural Integrity and Systems Performance)

  2. Centre for Manufacturing and Materials Engineering, Coventry University, Priory Street, Coventry, CV1 5FB, U.K.

    Bilal Ahmad (Research Associate) & Michael E. Fitzpatrick (Professor, Lloyd´s Register Foundation Chair in Structural Integrity and Systems Performance)

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  1. Bilal Ahmad
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  2. Michael E. Fitzpatrick
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Correspondence to Michael E. Fitzpatrick.

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Manuscript submitted June 5, 2015.

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Ahmad, B., Fitzpatrick, M.E. Minimization and Mitigation of Wire EDM Cutting Errors in the Application of the Contour Method of Residual Stress Measurement. Metall Mater Trans A 47, 301–313 (2016). https://doi.org/10.1007/s11661-015-3231-7

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  • DOI: https://doi.org/10.1007/s11661-015-3231-7

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