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Milling performance of Inconel 718 based on DC short electric arc machining with graphite and W-Ag electrode materials

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Abstract

In order to solve the problems of poor dimensional accuracy, high-specific energy consumption (SEC), and poor surface integrity in DC short electric arc machining (SEAM), this paper proposes to use W-Ag alloy as the electrode material for machining nickel-based alloy (Inconel 718). Firstly, the effect of voltage and electrode material (graphite and W-Ag alloy) on the material removal rate (MRR), relative electrode wear rate (REWR), surface roughness (Sa), and SEC were investigated, and current and voltage during machining were measured by a multichannel data acquisition system. In addition, the surface morphology, cross section, and element distribution after machining were analyzed. The experimental results showed that W-Ag alloy as a tool electrode can obtain better performance in SEAM; its MRR reach 6314 mm3/min at 30 V which is twice as high as graphite electrode. The SEC of W-Ag alloy electrode is 32.64 kJ/cm3, significantly lower than that of graphite electrode with 84.16 kJ/cm3. The surface roughness is lower after machining with W-Ag alloy electrode, and the thermal damage layer is only half of that machined with graphite electrode.

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Funding

This research was supported by the Natural Science Foundation of China (Grant No. 51765063), the Key Research and Development Projects in the Autonomous Region (Grant No. 2018B02009-1), and Xinjiang Uighur Autonomous Region Talent Project (Grant No. 10020000204).

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Authors and Affiliations

  1. School of Mechanical Engineering, Xinjiang University, Urumqi, 830047, China

    Zhouwei Liu, Xiangyu Dai, Jianping Zhou, Yan Xu & Zongjie Zhou

  2. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, 518055, Guangdong, China

    Kai Liu

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  1. Zhouwei Liu
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  2. Kai Liu
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  3. Xiangyu Dai
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  4. Jianping Zhou
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  5. Yan Xu
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Contributions

Zhouwei Liu, data curation and writing–original draft preparation. Kai Liu, conceptualization and methodology. Xiangyu Dai, experimental planning. Jianping Zhou, reviewing and editing. Yan Xu, investigation and validation. Zongjie Zhou, data processing.

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Correspondence to Kai Liu or Jianping Zhou.

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Liu, Z., Liu, K., Dai, X. et al. Milling performance of Inconel 718 based on DC short electric arc machining with graphite and W-Ag electrode materials. Int J Adv Manuf Technol 122, 2253–2265 (2022). https://doi.org/10.1007/s00170-022-10029-1

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