Skip to main content
SpringerLink
Log in

Effect of pulse current parameters on electroplastically assisted dry cutting performance of W93NiFe alloy

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Tungsten alloys have excellent properties such as high strength, high hardness, high melting point, and high specific gravity, which have been widely used in many cutting-edge scientific fields such as aerospace and military. In order to solve the problems of poor surface quality and severe tool wear in tungsten alloy cutting, conventional dry turning and electroplastically assisted dry turning with different electrical parameters were carried out to study the effects of electroplasticity on surface roughness, surface defects, tool wear, and chip morphology of W93NiFe alloy. The results showed that the electroplastically assisted dry turning process improved the surface quality of W93NiFe alloy. The surface roughness value decreases gradually with the increase of pulse voltage and reaches the minimum value at the pulse voltage of 80 V, with the maximum reduction of 38.94% compared with conventional dry turning. However, too high pulse voltage causes an increase in the surface roughness value. When the pulse voltage was increased from 80 to 90 V, the surface roughness increased by 29.63%. At a pulse voltage of 70 V, the surface roughness value did not change much for different pulse current frequency conditions. Compared to conventional dry turning, electroplastically assisted cutting reduced the degree of machined surface defects in the material and tool wear, but it could lead to the formation of built-up edge at the tool tip. After the pulsed current was applied, the chip curl radius and pitch were smaller, and it was easier to form strip chips with longer transverse lengths. The results provide a reliable reference for electroplastically assisted cutting in the future.

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

Similar content being viewed by others

References

  1. Yu C (2015) Impact experimental and nanoscopic mechanical simulation investigation of tungsten alloy for penetrator. In: Dissertation. Beijing Institute of Technology

  2. Sagar CK, Priyadarshini A, Gupta AK (2021) Experimental investigations on the effect of tungsten content on the machining behaviour of tungsten heavy alloys. Def Sci J 71(2):162–170. https://doi.org/10.14429/dsj.71.15857

    Article  CAS  Google Scholar 

  3. Huang Y, Zhou X, Hua N, Que W, Chen W (2018) High temperature friction and wear behavior of tungsten-copper alloys. Int J Refract Metal Hard Mater 77:105–112. https://doi.org/10.1016/j.ijrmhm.2018.08.001

    Article  CAS  Google Scholar 

  4. Liu J, Zhang K (2016) Influence of electric current on superplastic deformation mechanism of 5083 aluminium alloy. Mater Sci Technol 32(6):540–546. https://doi.org/10.1179/1743284715Y.0000000120

    Article  CAS  Google Scholar 

  5. Magargee J, Morestin F, Cao J (2013) Characterization of flow stress for commercially pure titanium subjected to electrically assisted deformation. J Eng Mater Technol 135(4):41003–41003. https://doi.org/10.1115/1.4024394

    Article  CAS  Google Scholar 

  6. Liu K, Dong X, Xie H, Peng F (2015) Effect of pulsed current on the deformation behavior of AZ31B magnesium alloy. Mater Sci Eng, A 623:97–103. https://doi.org/10.1016/j.msea.2014.11.039

    Article  CAS  Google Scholar 

  7. Xie H, Dong X, Liu K, Ai Z, Peng F, Wang Q, Chen F, Wang J (2015) Experimental investigation on electroplastic effect of DP980 advanced high strength steel. Mater Sci Eng, A 637:23–28. https://doi.org/10.1016/j.msea.2015.04.016

    Article  CAS  Google Scholar 

  8. Ross CD, Irvin DB, Roth JT (2007) Manufacturing aspects relating to the effects of direct current on the tensile properties of metals. J Eng Mater Technol 129(2):342–347. https://doi.org/10.1115/1.2712470

    Article  CAS  Google Scholar 

  9. Ruszkiewicz BJ, Grimm T, Ragai I, Mears L, Roth JT (2017) A review of electrically-assisted manufacturing with emphasis on modeling and understanding of the electroplastic effect. J Manufac Sci Eng 139(11):110801–110816. https://doi.org/10.1115/1.4036716

  10. Zheng MX, Zhu YH, Tang GY (1998) Comments on electroplastic drawing and its structure evolution. Journal of Tsinghua University (Science and Technology) 38(02):30–34. https://doi.org/10.16511/j.cnki.qhdxxb.1998.02.008

  11. Deng H, Dong XH (2019) Influence of electroplastic effect on forming limit of 5A90 Al-Li alloy. J Plast Eng 06:114–119. https://doi.org/10.3969/j.issn.1007-2012.2019.06.017

    Article  Google Scholar 

  12. Kim MJ, Lee K, Oh KH, Choi IS, Yu HH, Hong ST, Han HN (2014) Electric current-induced annealing during uniaxial tension of aluminum alloy. Scripta Mater 75:58–61. https://doi.org/10.1016/j.scriptamat.2013.11.019

    Article  CAS  Google Scholar 

  13. Andre D, Burlet T, Körkemeyer F, Gerstein G, Gibson JL, Sandlöbes-Haut S, Korte-Kerzel S (2019) Investigation of the electroplastic effect using nanoindentation. Mater Des 183:108153. https://doi.org/10.1016/j.matdes.2019.108153

    Article  CAS  Google Scholar 

  14. Shi W, Dong XH (2019) Multi-physical field coupled analysis of electric current assisted tension of AZ31B magnesium alloy. J Plast Eng 06:106–113. https://doi.org/10.3969/j.issn.1007-2012.2019.06.016

    Article  Google Scholar 

  15. Sun LN, Li Q, Li M (2020) Experimental study on electro-plastic effect in affect duration of single electric pulse in rolling. J Plast Eng 10:21–26. https://doi.org/10.3969/j.issn.1007-2012.2020.10.004

    Article  Google Scholar 

  16. Tian HY, Tang GY, Ding F, Xu ZH, Jiang YB (2017) Research on electroplastic drawing of Mg-alloy wire. Nonferrous Metals Eng 2:10–13. https://doi.org/10.3969/j.issn.2095-1744.2007.02.003

  17. Ghiotti A, Bruschi S, Simonetto E, Gennari C, Calliari I, Bariani P (2018) Electroplastic effect on AA1050 aluminium alloy formability. CIRP Ann 67(1):289–292. https://doi.org/10.1016/j.cirp.2018.04.054

    Article  Google Scholar 

  18. Li DL, Li YT, Yu EL, Han Y, Liu F (2018) Theoretical and experimental study of the drawing force under a current pulse. Int J Adv Manufac Technol 97(1):1047–1051. https://doi.org/10.1007/s00170-018-1896-y

    Article  Google Scholar 

  19. Qian L, Zhan L, Zhou B, Zhang X, Liu S, Lv Z (2021) Effects of electroplastic rolling on mechanical properties and microstructure of low-carbon martensitic steel. Mater Sci Eng, A 812:141144. https://doi.org/10.1016/j.msea.2021.141144

    Article  CAS  Google Scholar 

  20. Huang HC, Liu MJ, Sun M, Jiang P (2021) Microstructure and properties of V-Ti-Ni alloy for hydrogen separation treated by electroplastic rolling. Heat Treat Metals 46(3):153–158. https://doi.org/10.13251/j.issn.0254-6051.2021.03.031

    Article  CAS  Google Scholar 

  21. Zhao Y, Peng L, Lai X (2018) Influence of the electric pulse on springback during stretch U-bending of Ti6Al4V titanium alloy sheets. J Mater Process Technol 261:12–23. https://doi.org/10.1016/j.jmatprotec.2018.05.030

    Article  CAS  Google Scholar 

  22. Lv Z, Zhou Y, Zhan L, Zang Z, Zhou B, Qin S (2021) Electrically assisted deep drawing on high-strength steel sheet. Int J Adv Manufac Technol 112(3):763–773. https://doi.org/10.1007/s00170-020-06335-1

    Article  Google Scholar 

  23. Potapova AA, Resnina NN, Stolyarov VV (2014) Shape memory effects in TiNi-based alloys subjected to electroplastic rolling. J Mater Eng Perform 23(7):2391–2395. https://doi.org/10.1007/s11665-014-1046-0

    Article  CAS  Google Scholar 

  24. Liu DD (2019) Suppression of edge crack of cold rolled magnesium alloy by high pulse current and its mechanism analysis. Dissertation, Yanshan University. https://doi.org/10.27440/d.cnki.gysdu.2019.000562

  25. Song H, Wang ZJ (2013) Improvement in formability of TiAl and Ti alloys by high density electropulsing. Mater Sci Technol 21(05):117–124. https://doi.org/10.11951/j.issn.1005-0299.20130520

  26. Li XF, Jiao GP, Jiang J, Chen J (2019) Effect of pulse current frequency on mechanical properties of TC4 titanium alloy with prefabricated defects. Rare Metal Mater Eng 48(8):2655–2660

    CAS  Google Scholar 

  27. Huang BT, Gao YF (2020) Experimental study on electroplasticity assisted milling of GH4169 superalloy. J Plast Eng 27(12):82–87. https://doi.org/10.3969/j.issn.1007-2012.2020.12.012

    Article  Google Scholar 

  28. Ulutan D, Pleta A, Mears L (2015) Electrically-assisted machining of titanium alloy ti-6Al-4V and nickel-based alloy IN-738: an investigation. International Manufacturing Science and Engineering Conference: American Society of Mechanical Engineers 56826:V001T02A013. https://doi.org/10.1115/MSEC2015-9465

  29. Ruszkiewicz BJ, Gendreau E, Niaki FA, Mears L (2018) Electroplastic drilling of low-and high-strength steels. J Manuf Sci Eng 140(6):1017–1031. https://doi.org/10.1115/1.4039648

    Article  Google Scholar 

  30. Ruszkiewicz BJ, Akhavan Niaki F, Mears L, Gendreau E (2017) An investigation of electroplastic drilling of mild steel. International Manufacturing Science and Engineering Conference: American Society of Mechanical Engineers 50725: V001T02A013. https://doi.org/10.1115/MSEC2017-2766

  31. Egea AJS, Rojas HAG, Montaña CAM, Echeverri VK (2015) Effect of electroplastic cutting on the manufacturing process and surface properties. J Mater Process Technol 222:327–334. https://doi.org/10.1016/j.jmatprotec.2015.03.018

    Article  CAS  Google Scholar 

  32. Zhang S, Wang HB, Zhang B, Song GL, Wang XL, Han L, Tang GY (2018) Effect of electropulsing assisted cutting process on cutting properties of quenched GCr15 bearing steel. Rare Metal Mater Eng 47(2):574–580

  33. Zhao ZF, Qi JG, Wang JZ (2013) Effects of electric pulse treatment on γ phase in silicon brass. Foundry Technol 34(9):1108–1111

    CAS  Google Scholar 

  34. Dobras D, Bruschi S, Simonetto E, Rutkowska-Gorczyca M, Ghiotti A (2020) The effect of direct electric current on the plastic behavior of AA7075 aluminum alloy in different states of hardening. Materials 14(1):73. https://doi.org/10.3390/ma14010073

  35. Ye SS, Zhao D, Yang Y, Yang G, Yin DQ, Zhou Y (2017) Flow stress analysis of TC4 titanium alloy during electroplastic effect. Rare Metal Mater Eng 06:1572–1577

  36. Ma R, Zhang XF (2022) Refining the microstructure to strengthen casting titanium alloy by electric pulse. Mater Sci Eng, A 849:143519. https://doi.org/10.1016/j.msea.2022.143519

    Article  CAS  Google Scholar 

  37. Wang HB (2016) Research on the electropulsing assisted turning and ultrasonic-electropulsing coupling surface process for the 304 stainless steel. Dissertation, Tsinghua University

  38. Zhou YZ, Zeng Y, He GH, Zhou BL (2001) The healing of quenched crack in 1045 steel under electropulsing. J Mater Res 16(1):17–19. https://doi.org/10.1557/JMR.2001.0005

    Article  CAS  Google Scholar 

  39. Qin R, Su S (2002) Thermodynamics of crack healing under electropulsing. J Mater Res 17(8):2048–2052. https://doi.org/10.1557/JMR.2002.0303

    Article  CAS  Google Scholar 

  40. Wang CH (2021) Micro wear mechanism of TiAlN coated carbide tool in 93W machining. Dissertation, Southwest Jiaotong University. https://doi.org/10.27414/d.cnki.gxnju.2021.000620

  41. Wang H, Chen L, Liu D, Song G, Tang G (2015) Study on electropulsing assisted turning process for AISI 304 stainless steel. Mater Sci Technol 31(13):1564–1571. https://doi.org/10.1179/1743284715Y.0000000034

    Article  CAS  Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (52175431).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin, 30022, China

    Lixiang Zhao, Guangjun Chen, Jie Liu, Hong Wei & Jiashuai Huang

Authors
  1. Lixiang Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guangjun Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jie Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hong Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jiashuai Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Lixiang Zhao, Guangjun Chen, Jie Liu, Hong Wei, and Jiashuai Huang. The first draft of the manuscript was written by Lixiang Zhao, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Guangjun Chen.

Ethics declarations

Competing interests

The authors declare no competing interests.

Additional information

Publisher's note

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

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhao, L., Chen, G., Liu, J. et al. Effect of pulse current parameters on electroplastically assisted dry cutting performance of W93NiFe alloy. Int J Adv Manuf Technol 131, 2123–2131 (2024). https://doi.org/10.1007/s00170-022-10762-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10762-7

Keywords

Search

Navigation