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Investigation on the kerf and surface formation in the magnetic field-assisted WEDM-LS based on successive discharges

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Abstract

Magnetic field-assisted low-speed wire electrical discharge machining (MF-assisted WEDM-LS) is an effective technique to improve the surface quality of the workpiece. This paper presents a successive removing model to predict kerf width and the surface topography of nickel–titanium (Nitinol) shape memory alloy in different parameters. Firstly, the motion of an electron was calculated in the magnetic field. It could be obtained that if the length of the discharge channel path was the same with the condition that in traditional WEDM-LS, the width of the discharge gap was decreased because of the deflection of the electron trajectory caused by the magnetic field. Then, a modified gauss heat source equation was derived by calculating the incident angle of the discharge channel. Based on the principle of conservation of energy, the shape of the crater in different parameters was emulated. Moreover, an electrothermal coupling model was established to investigate the surface formation in the successive discharges process. The simulation results show that the average value of the surface roughness of the workpiece in WEDM-LS with magnetic field assisted was decreased by 12.3% compared with that in traditional WEDM-LS. Eventually, experiments of kerf and surface quality were carried out respectively. The experimental results showed that the kerf decreased from 376.2 to 361.7 μm in the magnetic field intensity of 0.4 T. The surface topographies of the workpieces showed good agreement with the simulation results, and the average relative error of surface roughness between simulated results and experimental results is 8.7%.

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Acknowledgements

The authors thanked the Natural Science Foundation of Shanghai for providing the necessary support for the study.

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Authors and Affiliations

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

    Yan Wang, Qingzhong Wang, Jianguo Liu & Yongxin Wang

  2. School of Materials Science and Engineering, University of Shanghai for Science and Technology, Shanghai, 200093, China

    Wei Xiong

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  1. Yan Wang
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  2. Qingzhong Wang
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  3. Wei Xiong
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  4. Jianguo Liu
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  5. Yongxin Wang
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Contributions

Yan Wang: conceptualization, methodology, supervision, writing, review, and editing. Chengzhen Wu: formal analysis and revision. Yongxin Wang: visualization preparation and validation. Liangliang Chu: visualization and figure editing. Wei Xiong: resources and data curation. Jianguo Liu: resources and investigation. Qingzhong Wang: software programming and writing the original draft.

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Correspondence to Yan Wang.

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Wang, Y., Wang, Q., Xiong, W. et al. Investigation on the kerf and surface formation in the magnetic field-assisted WEDM-LS based on successive discharges. Int J Adv Manuf Technol 114, 841–856 (2021). https://doi.org/10.1007/s00170-021-06906-w

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