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Effects of processing parameters on the surface roughness of Zr-based bulk metallic glass processed by wire electrical discharge machining

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Abstract

Bulk metallic glass (BMG) is one of the predominant materials that are progressively used in the aerospace, medical devices, electronics, sporting goods, and engineering materials. Making of components by BMG is still confrontation. Conventional methods of machining are restricted in use due to more tool wear and slower processing efficiency. Non-traditional methods of machining have been widely used for processing hard materials. Wire electrical discharge machining (WEDM) is one among the promising approaches of machining for hard and conductive materials, especially for the new BMG metal material. The preliminary aim of this exploration is to predict the temperature field distribution using the modified Gaussian heat source mode during WEDM multi-pulse discharge process. The effects of various variables (pulse off time and peak current) on the pit depth and surface roughness were investigated. The influence of the main parameters on the machining performance was investigated using Taguchi’s orthogonal arrays. The excellent surface quality is obtained at the optimized condition of a pulse on time of 4 μs, pulse off time of 25 μs, and a peak current of pulse on time.

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Abbreviations

T :

Temperature (K)

t :

Time (s)

c :

Specific heat capacity of the material (J/(kg∙K))

k :

Thermal conductivity of the material (W/(m2·K))

ρ :

Material density (kg/m3)

R(t):

Radius of the heat source (m)

I :

Discharge current (A)

t on :

Pulse on time (s)

q max :

Maximum heat flow

r :

Radial cylindrical coordinate

z :

Axial cylindrical coordinate

R pc :

Radius of the discharge channel (m)

η :

Energy distribution factor

U :

Discharge maintenance voltage (V)

x i :

Distance between discharge points (m)

Ra:

Surface roughness (μm)

r c :

Radius of the crater (μm)

r s :

Radius of the discharge channel (μm)

s :

Depth of the crater (μm)

CE :

Cutting efficiency

T :

Processing time (s)

d :

Workpiece diameter

ON :

Pulse on time (μs)

OFF :

Pulse off time (μs)

IP :

Peak current (A)

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Funding

The work described in this paper was supported by the Fundamental Research Funds for the Central Universities (grant no. JZ2022HGTB0247).

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Authors and Affiliations

  1. School of Mechanical Engineering, Hefei University of Technology, Hefei, 230009, China

    Huohong Tang, Maohu Cheng, Weijie Chang, Bolin Dong, Qin Yang & Shunhua Chen

  2. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education of China, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Yingyue Yin

  3. National Demonstration Center for Experimental Mechanical Engineering Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Yingyue Yin

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  1. Huohong Tang
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Contributions

Huohong Tang: conceptualization, methodology, writing—original draft. Maohu Cheng: visualization, data curation. Weijie Chang: validation, supervision, conception, writing—review and editing. Yingyue Yin: validation, supervision, conception, writing—review and editing. Bolin Dong: software, investigation. Qin Yang: visualization, data curation. Shunhua Chen: methodology, supervision, funding acquisition.

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Correspondence to Weijie Chang, Yingyue Yin or Shunhua Chen.

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Tang, H., Cheng, M., Chang, W. et al. Effects of processing parameters on the surface roughness of Zr-based bulk metallic glass processed by wire electrical discharge machining. Int J Adv Manuf Technol 128, 41–56 (2023). https://doi.org/10.1007/s00170-023-11829-9

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