Determining cutting parameters in wire EDM based on workpiece surface temperature distribution
- 777 Downloads
The material removal process in wire electrical discharge machining (WEDM) may result in work-piece surface damage due to the material thermal properties and the cutting parameters such as varying on-time pulses, open circuit voltage, machine cutting speed, and dielectric fluid pressure. A finite element method (FEM) program was developed to model temperature distribution in the workpiece under the conditions of different cutting parameters. The thermal parameters of low carbon steel (AISI4340) were selected to conduct this simulation. The thickness of the temperature affected layers for different cutting parameters was computed based on a critical temperature value. Through minimizing the thickness of the temperature affected layers and satisfying a certain cutting speed, a set of the cutting process parameters were determined for workpiece manufacture. On the other hand, the experimental investigation of the effects of cutting parameters on the thickness of the AISI4340 workpiece surface layers in WEDM was used to validate the simulation results. This study is helpful for developing advanced control strategies to enhance the complex contouring capabilities and machining rate while avoiding harmful surface damage.
KeywordsWEDM Thermal damage FEM Temperature distribution Cutting parameters
Unable to display preview. Download preview PDF.
This research was supported by the National Science Foundation’s Engineering Research Center for Reconfigurable Manufacturing Systems. The work is a partnership between the University of Michigan and Morgan State University in advanced manufacturing processes.
- 2.Ho KH, Newman ST (2003) State of the art electrical discharge machining (EDM). Advanced Manufacturing Systems and Technology Center, Wolfson School of Mechanical and Manufacture Engineering, UKGoogle Scholar
- 4.Wojtas AS, Suominen L, Shaw BA, Evans JT (1998) Detection of thermal damage in steel components after grinding using the magnetic Barkhausen noise method. Proceedings of the 7th ECNDT, Copenhagen, 3(9)Google Scholar
- 5.Velterop L (2003) Influence of wire electrical discharge machining on the fatigue properties of high strength stainless steel. National Aerospace Laboratory NLR, Amsterdam, The NetherlandsGoogle Scholar
- 6.Blok H (1938) Theoretical study of temperature rise at surfaces of actual contact under oiliness lubricating conditions. Proceedings of general discussion on lubrication and lubricants. Institute of Mechanical Engineers, London, 2:222–235Google Scholar
- 7.Jaeger JC (1942) Moving sources of heat and the temperature at sliding contacts. J Proc Roy Soc NSW 76:133–228Google Scholar
- 8.Hahn RS (1951) On the temperature developed at the shear plane in the metal cutting process. Proceedings of the first US national congress of applied mechanics, ASME, pp 661–666Google Scholar
- 9.Erden A, Kaftanoglu B (1980) Heat transfer modeling of electric discharge machining. Proceeding of the 21st MTDR conference, Swansea, UK, pp 351–358Google Scholar
- 12.Biermann D et al (1997) Modeling and simulation of work-piece temperature in grinding by finite element method. Mach Sci Technol 1(2)Google Scholar
- 13.Bhattacharya R, Jain VK, Ghoshdastidar S (1996) Numerical simulation of thermal erosion in EDM process. J Inst Eng 77:13–19Google Scholar
- 16.Shi J (2004) Prediction of thermal damage in super finish hard machined surfaces. Dissertation, Purdue University, USAGoogle Scholar