Advertisement

Surface Roughness Improvement by Removal of Recast Layer on Wire Electrical Discharge Machined Surface Through Abrasive Flow Finishing Machine

  • M. A. ManjunathEmail author
  • A. Murugan
  • Prakash Vinod
  • N. Balashanmugam
Conference paper
Part of the Lecture Notes on Multidisciplinary Industrial Engineering book series (LNMUINEN)

Abstract

Wire electrode discharge machining (WEDM) is a widely accepted process for machining of precision and complex geometry. Generally the spark produced during the WEDM process on the workpiece surfaces forms a layer of recast. It is one of the challenging aspects to remove this recast layer from a complex surface. The present research investigates the removal of WEDM recast layer and surface roughness improvement on the components having internal complex geometry on stainless steel (SS 410) material. The study also explores the effect of abrasive flow finishing for multiple components by stacking parallel to each other for simultaneous finishing through suitable fixture. The featuring of WEDM machined surface before and after AFFM process is examined through scanning electron microscope (SEM). Additionally, EDS reveals the noticeable amount of electrode material deposited on the component, which is removed after AFFM. The improvement in the surface roughness has been also noticed through surface roughness tester, Form Talysurf.

Keywords

EDM recast layer Abrasive flow finishing machine (AFFM) Surface roughness SEM analysis EDS 

References

  1. 1.
    Williams, R.E., Rajurkar, K.P.: Study of wire electrical discharge machined surface characteristics. J. Mater. Process. Technol. 28, 127–138 (1991)CrossRefGoogle Scholar
  2. 2.
    Sachin, B., Shrinivas, S., Vishal, B.: Study and analysis of recast layer formation during wire electo discharge machining process. Int. J. Innov. Res. Sci., Eng. Technol., 8032–8039Google Scholar
  3. 3.
    Kohut, T.: Surface finishing with abrasive flow machining. SME technical paper, 35–43 (1989)Google Scholar
  4. 4.
    Loveless, T.R., Williams, K.P., Rajurkar, K.P.: A study of the effect of abrasive-flow finishing on various machined surfaces. J. Mater. Process. Technol. 47, 133–151 (1994)CrossRefGoogle Scholar
  5. 5.
    Tzeng, H.-J., Yan, B.-H., Hsu, R.-T., Cho, H.-M.: Finishing effect of abrasive flow machining on micro slit fabricated by wire EDM. Int. J. Manuf. Technol. 34, 649–656 (2007)CrossRefGoogle Scholar
  6. 6.
    Lin, Y.-C., Chow, H.-M., Yan, B.-H., Tzeng, H.-J.: Effects of finishing in abrasive fluid machining on microholes fabricated by EDM. Int. J. Manuf. Technol. 33, 489–497 (2007)CrossRefGoogle Scholar
  7. 7.
    Kenda, J., Pusavec, F., Kermouche, G., Kopac, J.: Surface integrity in abrasive flow machining of hardened tool steel AISI D2. Procedia Eng. 19, 172–177 (2011)CrossRefGoogle Scholar
  8. 8.
    Toshimitsu, R., Okada, A., Kitada, R., Okamoto, Y.: Improvement in surface characteristics by EDM with chromium powder mixed fluid. In: 18th CIRP Conference on Electro Physical and Chemical Machining (ISEM XVIII), vol. 42, pp. 231–235 (2016)CrossRefGoogle Scholar
  9. 9.
    Khan, A.A, Mohiuddin, A.K.M., Latif, M.A.A.: Improvement of MRR and surface roughness during electrical discharge machining (EDM) using aluminium oxide powder mixed dielectric fluid. In: IOP Conference Series: Materials Science and Engineering, vol. 290, p. 012063 (2018)CrossRefGoogle Scholar
  10. 10.
    Amineh, S.K., Tehrani, A.F., Mohammadi, A.: Improving the surface quality in wire electrical discharge machined specimens by removing the recast layer using magnetic abrasive finishing method. Int. J. Manuf. Technol. (2012)Google Scholar
  11. 11.
    Manjunath, M.A., Abhinav, K., Vinod, P., Balashanmugam, N.: Simulation of force generated and material removal in abrasive flow finishing for aluminium material. COPEN 10, 765–768 (2017)Google Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  • M. A. Manjunath
    • 1
    Email author
  • A. Murugan
    • 1
  • Prakash Vinod
    • 1
  • N. Balashanmugam
    • 1
  1. 1.Nano Manufacturing Technology Centre, Central Manufacturing Technology InstituteBangaloreIndia

Personalised recommendations