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On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model

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Abstract

Structured abrasive tools (SATs) are considered as one of the next-generation abrasive tool solutions due to their superior ability to transport cutting fluids into grinding zones to lower grinding temperature and therefore enable high-quality machined surfaces. There are several SAT fabrication methods including mechanical, electroplating, brazing, and laser-based methods. Mechanical methods cannot produce SATs with small-sized structures due to significant contact forces, while electroplating has poor controllability of abrasive grain allocations. Brazing requires special machines with high-precision motion control, while laser-based methods need significant efforts on laser parameter selection and optimization. With this, here, we present a multiple-pass rotary wire electrical discharge machining (MPRWEDM) method to address the aforementioned limitations. We also develop a theoretical model of the created kerf profile during the MPRWEDM so as to enable controllable fabrication of SATs. The model was experimentally validated, showing a decent relative error of 9.8%. The nonlinear multiple-pass effect was studied both analytically and experimentally. Based on MPRWEDM, not only the SAT with designed grooves but also the structured surface (having an array of pyramid geometries) generated by the SAT were successfully created, proving the great potential of MPRWEDM in controllable production of even more advanced tools.

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Abbreviations

a p :

Cut depth (m)

d m :

Melting depth (m)

h :

Equivalent workpiece thickness (m)

I :

Peak discharge current (A)

K :

Kerf width (m)

k :

Gap distance between the kerf profile and any wire electrode point (m)

L :

Distance between wire electrode points and workpiece rotation A-axis

MRR :

Material removal rate (mm3*min−1)

N :

Multiple pass number

num :

The number of non-repeated discharge sparks

p :

Wire feed distance in Y direction (m)

R c :

Single pulse discharge center radius (m)

R d :

Plasma channel radius (m)

r :

Wire electrode radius (m)

t num :

Duration time of num discharge sparks (s)

t off :

The pulse interval (s)

t on :

The pulse width (s)

v m :

Wire moving speed (m*s−1)

v s :

Relative wire cut speed (m*s−1)

w :

Wire feed distance in Y direction (m)

∆B n :

Increment of kerf depth BBN (m)

∆C n :

Increment of kerf depth CCN (m)

θ :

The angle of extension line OC0 and line OA (m)

ω :

Workpiece rotation speed (rad*s−1)

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Funding

This work was supported by the National Natural Science Foundation of China (51975302, 52175417), the Zhejiang Provincial Natural Science Foundation (LY20E050014, LQ22E050014, LQ20E050006), the Research Project of Key Laboratory of E&M (Zhejiang University of Technology) (EM202012014), the State Key Laboratory of Mechanical System and Vibration (MSV202120), and the Ningbo Municipal Natural Science Foundation (2019A610154, 202003N4184).

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Authors and Affiliations

  1. Nottingham Ningbo China Beacons of Excellence Research and Innovation Institute, Ningbo, 315048, People’s Republic of China

    Bixuan Wang, Gongyu Liu & Hao Nan Li

  2. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Ningbo China, Ningbo, 315100, China

    Bixuan Wang & Robert S. Pierce

  3. Faculty of Mechanical Engineering & Mechanics, Ningbo University, Ningbo, 315211, China

    Yong Jie Zhao

  4. Key Laboratory of Marine Materials and Related Technologies, Zhejiang Key Laboratory of Marine Materials and Protective Technologies, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, 315201, China

    Bo Wang

  5. State Key Laboratory Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

    Qingzhen Bi

  6. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China

    Huan Qi

  7. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710054, People’s Republic of China

    Xuewei Fang

  8. School of Aerospace, University of Nottingham Ningbo China, Ningbo, 315100, China

    Hao Nan Li

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  1. Bixuan Wang
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Contributions

All authors contributed to the material preparation, data collection, and experimental study. All authors commented on previous versions of the manuscript. The first draft of the manuscript was written by Bixuan Wang, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Hao Nan Li.

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Wang, B., Liu, G., Zhao, Y.J. et al. On the creation of structured abrasive tools via multiple-pass rotary wire EDM: A geometrical model. Int J Adv Manuf Technol 126, 3503–3522 (2023). https://doi.org/10.1007/s00170-023-11276-6

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