Skip to main content
SpringerLink
Log in

An investigation on machining large removal cylindrical parts using WEDM with contour approximation method

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The application of wire EDM to the machining of cylindrical parts is an emerging research topic. The current research is mainly focused on the processing of microcylindrical parts, and the processing removal of microparts is usually small. In the complete machining process, especially during rough machining, the removal amount of the workpiece is usually large. In recent years, there have been few studies in this area. This paper proposes the application of WEDM with contour approximation method (CAM-WEDM) to the machining of cylindrical parts with large removal volume. First, the basic principle of the contour approximation method is introduced, and the machining process is divided into three parts: roughing, semi-finishing and finishing. Roughing corresponds to polygon cutting. Second, the various indicators of polygon cutting are analyzed. The influence of the number of polygonal sides on the residual height and residual area is analyzed. Two methods are proposed for polygon cutting: sequential cutting and multiple cutting. The calculation formulas for the machining volume of the two methods are deduced. By comparing the two methods, it is found that different methods are applicable to different part sizes. At last, machining experiments were carried out. The selection of residual variables and the determination of polygon machining methods are detailed. The process parameters and machining time of each stage are listed. In addition, the measurement results of each stage of the machining are also analyzed. At the same time, by comparing with the general WEDT, it is concluded that CAM-WEDM can effectively process cylindrical parts with large removal volume.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Data availability

All data generated or analyzed during this study are included in this published paper.

References

  1. Haddad MJ, Tehrani AF (2008) Investigation of cylindrical wire electrical discharge turning (CWEDT) of AISI D3 tool steel based on statistical analysis. J Mater Process Technol 98:77–85. https://doi.org/10.1016/j.jmatprotec.2007.06.059

    Article  Google Scholar 

  2. Haddad MJ, Fadaei Tehrani A (2008) Material removal rate (MRR) study in the cylindrical wire electrical discharge turning (CWEDT) process. J Mater Process Technol 199:369–378. https://doi.org/10.1016/j.jmatprotec.2007.08.020

    Article  Google Scholar 

  3. Mohammadi A, Tehrani AF, Emanian E, Karimi D (2008) Statistical analysis of wire electrical discharge turning on material removal rate. J Mater Process Technol 205:283–289. https://doi.org/10.1016/j.jmatprotec.2007.11.177

    Article  Google Scholar 

  4. Uhlmann E, Piltz S, Oberschmidt D (2008) Machining of micro rotational parts by wire electrical discharge grinding. Production Engineering-Research and Development 2:227–233. https://doi.org/10.1007/s11740-008-0094-4

    Article  Google Scholar 

  5. Janardhan V, Samuel GL (2010) Pulse train data analysis to investigate the effect of machining parameters on the performance of wire electro discharge turning (WEDT) process. Int J Mach Tools Manuf 50:775–788. https://doi.org/10.1016/j.ijmachtools.2010.05.008

    Article  Google Scholar 

  6. Weingärtner E, Wegener K, Kuster F (2012) Wire electrical discharge machining applied to high-speed rotating workpieces. J Mater Process Technol 212:1298–1304. https://doi.org/10.1016/j.jmatprotec.2012.01.005

    Article  Google Scholar 

  7. Mohammadi A, Tehrani AF, Abdullah A (2013) Introducing a new technique in wire electrical discharge turning and evaluating ultrasonic vibration on material removal rate. CIRP Conference on Electro Physical and Chemical Machining 6:583–588. https://doi.org/10.1016/j.procir.2013.03.005

    Article  Google Scholar 

  8. Aravind Krishnan S, Samuel GL (2013) Multi-objective optimization of material removal rate and surface roughness in wire electrical discharge turning. Int J Adv Manuf Technol 67:2021–2032. https://doi.org/10.1007/s00170-012-4628-8

    Article  Google Scholar 

  9. Giridharan A, Samuel GL (2015) Modeling and analysis of crater formation during wire electrical discharge turning (WEDT) process. Int J Adv Manuf Technol 77:1229–1247. https://doi.org/10.1007/s00170-014-6540-x

    Article  Google Scholar 

  10. Yingmou Z, Liang Tongsheng Gu, Lin ZW (2016) Machining of micro rotational parts with wire EDM machine. Procedia Manuf 5:849–856. https://doi.org/10.1016/j.promfg.2016.08.071

    Article  Google Scholar 

  11. Yao S, Yadong G (2017) Experimental study on the microelectrodes fabrication using low speed wire electrical discharge turning (LS-WEDT) combined with multiple cutting strategy. J Mater Process Technol 250:121–131. https://doi.org/10.1016/j.jmatprotec.2017.07.015

    Article  Google Scholar 

  12. Yao S, Yadong G, Yin L, Qiang Li, Yunguang Z (2017) Experimental study on surface characteristics and improvement of microelectrode machined by lows peed wire electrical discharge turning. Archives of Civil and Mechanical Engineering 17:964–977. https://doi.org/10.1016/j.acme.2017.02.004

    Article  Google Scholar 

  13. Yao S, Yadong G, Yin L, Ming C, Xiaoteng Ma, Pengfei Li (2018) Experimental investigation on effects of machining parameters on the performance of Ti-6Al-4V micro rotary parts fabricated by LS-WEDT. Archives of Civil and Mechanical Engineering 18:385–400. https://doi.org/10.1016/j.acme.2017.09.006

    Article  Google Scholar 

  14. Yao S, Yadong G (2018) Experimental study on fabricating spirals micro electrode and micro-cutting tools by low speed wire electrical discharge turning. J Mater Process Technol 258:271–285. https://doi.org/10.1016/j.jmatprotec.2018.04.007

    Article  Google Scholar 

  15. Yao S, Yadong G, Yongkang Ma, Yuying Y, Chunyou L (2018) An experimental study for evaluating the machining accuracy of LS-WEDT and its application in fabricating micro parts. Int J Adv Manuf Technol 98:969–983

    Article  Google Scholar 

  16. Yao S, Yadong G, Guoqiang Y, Ming C, Pengfei Li (2018) Experimental study on surface quality and machinability of Ti-6Al-4V rotated parts fabricated by low-speed wire electrical discharge turning. Int J Adv Manuf Technol 95:2601–2611. https://doi.org/10.1007/s00170-017-1360-4

    Article  Google Scholar 

  17. Xiang C, Zhenlong W, Yukui W, Guanxin C, Cheng G (2018) Micro reciprocated wire-EDM of micro-rotating structure combined multi-cutting strategy. Int J Adv Manuf Technol 97:2703–2714. https://doi.org/10.1007/s00170-018-2145-0

    Article  Google Scholar 

  18. Vignesh M, Ramanujam R (2019) Machining of Ti–6Al–4V using diffusion annealed zinc-coated brass wire in WEDHT. J Braz Soc Mech Sci Eng 41:359. https://doi.org/10.1007/s40430-019-1860-2

    Article  Google Scholar 

  19. Jees G, Manu R, Jose M (2019) Multi-objective optimization of roundness, cylindricity and areal surface roughness of Inconel 825 using TLBO method in wire electrical discharge turning (WEDT) process. J Braz Soc Mech Sci Eng 41:377. https://doi.org/10.1007/s40430-019-1880-y

    Article  Google Scholar 

  20. Jees G, Jose M, Manu R (2020) Determination of crater morphology and 3D surface roughness in wire electrical discharge turning of Inconel 825. Arab J Sci Eng 45:5109–5127. https://doi.org/10.1007/s13369-020-04372-2

    Article  Google Scholar 

  21. Sibabrata M, Dipankar B (2020) Formation of smallest cylindrical geometries by wire electrical discharge turning process. Mater Today 26:1500–1506. https://doi.org/10.1016/j.matpr.2020.02.310

    Article  Google Scholar 

  22. Bergs T, Tombul U, Mevissen D, Klink A, Brimmers J (2020) Load capacity of rolling contacts manufactured by wire EDM turning. Procedia CIRP 87:474–479. https://doi.org/10.1016/j.procir.2020.02.111

    Article  Google Scholar 

  23. Roy BK, Mandal A (2021) An investigation into the effect of wire inclination in wire-electrical discharge turning process of NiTi-60 shape memory alloy. J Manuf Process 64:739–749. https://doi.org/10.1016/j.jmapro.2021.01.050

    Article  Google Scholar 

  24. Pouyan T, Arameh E, Farayi M, Zeeshan Q, Babaei MR, Sebaey Tamer A (2021) Optimization of wire electrical discharge turning process trade-off between production rate and fatigue life. Int J Adv Manuf Technol 112:719–730. https://doi.org/10.1007/s00170-020-06351-1

    Article  Google Scholar 

  25. Yingmou Z, Ahmad F, Guojian He, Liang Tongsheng Gu, Lin ZW (2018) High-efficiency machining of large aspect-ratio rotational parts by rapid contour approaching WEDM. Int J Adv Manuf Technol 94:3577–3590. https://doi.org/10.1007/s00170-017-1090-7

    Article  Google Scholar 

Download references

Funding

This work is supported by the Shanxi Key R & D Program Project of China under grant number 201903D121048.

Author information

Authors and Affiliations

  1. School of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, China

    Huliang Ma, Yanqing Wang, Ming Lv & Shengqiang Yang

Authors
  1. Huliang Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yanqing Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ming Lv
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Shengqiang Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The proposal and realization of this technology were mainly completed by Huliang Ma and Yanqing Wang. Yang Shengqiang and Lv Ming provided guidance on research directions.

Corresponding authors

Correspondence to Huliang Ma or Yanqing Wang.

Ethics declarations

Ethical approval

Not applicable.

Consent to participate

Not applicable.

Consent to publish

Not applicable.

Research involving human and animal participants

The research content of this paper does not involve any people or animals.

Conflict of interest

Huliang Ma and Yanqing Wang have received research support from the funding. Shengqiang Yang and Ming Lv did not get paid from the funding.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ma, H., Wang, Y., Lv, M. et al. An investigation on machining large removal cylindrical parts using WEDM with contour approximation method. Int J Adv Manuf Technol 121, 393–406 (2022). https://doi.org/10.1007/s00170-022-09345-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-09345-3

Keywords

Search

Navigation