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Influence of the main technological parameters and material properties of the workpiece on the geometrical accuracy of the machined surface at wedm

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Abstract

Geometrical accuracy is currently one of the important parameters regarding the machined surfaces of components used in modern technical equipment. Even though the WEDM technology belongs to the precise final machining technologies, the most demanding requirements for the geometrical accuracy of the machined surface are not always met. These geometrical deviations consequently manifest themselves not only in the assembly of particular parts of the final product but also in their operation. In addition, errors of the geometrical accuracy of the machined surface also have negative effect on the serviceability of the finished parts and their overall service life. Even though these shortcomings are only minimally reflected in planar cuts, the production of circular profiles is a problem in particular. The important factors causing this poor quality are the technological parameters in combination with the specific physical and mechanical properties of the workpiece and wire electrode. Experimental research was therefore focused on identifying the influence of selected technological parameters and material properties of the workpiece on the size of geometrical deviations of the machined surface that occur at WEDM using CuZn37 wire electrode. In general, it is also a serious problem to maintain the prescribed geometrical tolerance of the machined surface in a narrow tolerance field. By exceeding it, the product becomes unsatisfactory. However, the problem is also achieved quality, which significantly exceeds the expected values. This essentially reduces productivity and worsens the economic efficiency of production. For this reason, it is ideal to achieve the exact required quality of the machined surface in terms of geometrical accuracy. Therefore, an algorithm of simulation software was proposed, which includes empirically determined mathematical models, based on which the software can predict the necessary setting of technological parameters, derived from the dimensional and material properties of the workpiece and wire. The mentioned solution thus will bring the geometrical accuracy of the production of circular holes in a narrow tolerance field to the customer’s requirements with a significant increase of the economic efficiency of production.

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Data Availability

All data is published with the paper.

Abbreviations

I :

Maximum peak current (A)

U :

Maximum electrical voltage (V)

t on :

Pulse on-time duration (μs)

t off :

Pulse off-time duration (μs)

A 1 :

Location of concentric circles with the center in C1,

A 2 :

Location of concentric circles with the center in C2,

H S :

Sample profile height (mm)

H PL :

Scanned line of the sample profile height (mm)

Fw :

Wire tension force (N)

C 1, C 2 :

Centers of circles

HSS:

High-speed steel

LSC:

Least squares mean circle

MTP:

Main technological parameters

MZC:

Minimum zone circles

MCC:

Minimum circumscribed circle

MIC:

Maximum inscribed circle

T :

Tolerance field

WEDM:

Wire electrical discharge machining

Δ :

Geometrical deviations of shape (μm)

Δ r1, Δ r2 :

Particular radial distances of the circles (mm)

y Ci :

Diameter of the workpiece profile (μm)

y Ci max/y Ci min :

Max./min. measured value of deviation (μm)

y Cmax/avg :

Measured value max./average deviations of circularity (μm)

λ :

Thermal conductivity (W.m−1.K−1)

κ :

Electrical conductivity (Siemens.m.mm−2)

ϕ E :

Wire electrode diameter (mm)

ϕ Ci :

Circle profile diameter (mm)

ϕ C1, ϕ C2 :

First/second measured value of the circle profile diameter (mm)

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Acknowledgements

The authors would like to thank the grant agency for supporting research work by the project VEGA 1/0205/19 and also by the Project of the Structural Funds of the EU, ITMS code 26220220103.

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Funding

This research was funded by Scientific Grant Agency of the Ministry of Education, Science, Research and Sport of the Slovak Republic, grant number VEGA 1/0205/19, and also by the Project of the Structural Funds of the EU, ITMS code 26220220103.

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Authors and Affiliations

  1. Faculty of Manufacturing Technologies of the Technical University of Košice with a seat in Prešov, Department of Automobile and Manufacturing Technologies, Štúrova 31, 08001, Prešov, Slovakia

    Ľuboslav Straka

  2. Faculty of Manufacturing Technologies of the Technical University of Košice with a seat in Prešov, Department of Industrial Engineering and Informatics, Bayerova 1, 08001, Prešov, Slovakia

    Ján Piteľ

  3. Faculty of Manufacturing Technologies of the Technical University of Košice with a seat in Prešov, Department of Process Engineering, Štúrova 31, 08001, Prešov, Slovakia

    Ivan Čorný

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Contributions

Methodology and data curation, ĽS; formal analysis, JP; design and performance of the experiments, ĽS and IČ; writing—original draft preparation, ĽS; project administration, ĽS and JP; funding acquisition and resources, ĽS. All the authors have read and agreed to the published version of the manuscript.

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Correspondence to Ľuboslav Straka.

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Straka, Ľ., Piteľ, J. & Čorný, I. Influence of the main technological parameters and material properties of the workpiece on the geometrical accuracy of the machined surface at wedm. Int J Adv Manuf Technol 115, 3065–3087 (2021). https://doi.org/10.1007/s00170-021-07313-x

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