Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters
Form-cutting tools are an economical choice for turning parts with defined profiles in mass production. The effects of the form contour of these tools—produced by the wire electrical discharge machining (WEDM) process—on tool quality were investigated in this research. This study focuses on reducing...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-10-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/14/11/1976 |
| _version_ | 1797458394782629888 |
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| author | Amir Alinaghizadeh Mohammadjafar Hadad Bahman Azarhoushang |
| author_facet | Amir Alinaghizadeh Mohammadjafar Hadad Bahman Azarhoushang |
| author_sort | Amir Alinaghizadeh |
| collection | DOAJ |
| description | Form-cutting tools are an economical choice for turning parts with defined profiles in mass production. The effects of the form contour of these tools—produced by the wire electrical discharge machining (WEDM) process—on tool quality were investigated in this research. This study focuses on reducing the adverse effects of the recast layer induced by WEDM on form-cutting tools. The basic component types of profile forms in form-cutting tools can be summarized by a combination of four modes, i.e., concave and convex arcs and flat and oblique surfaces. Hence, sample cutting tools with three different radii of convex and concave arcs and a flat surface were produced. During the WEDM operation, one-pass mode was used for roughing, two passes for semi-finishing, and three passes for finishing. Furthermore, the difference between the percentage of oxygen and carbon elements on the recast layer in the two areas above the workpiece or wire entry point and the bottom area of the workpiece or wire exit point was investigated. Finally, the influences of the direction, size of the curvature, and the number of passes in the wire electric discharge process on the recast layer were analyzed. It was observed that the recast layer thickness could be reduced by increasing the number of WEDM process. Additionally, the uniformity of the cutting contour was superior in the entry region of the wire going into the workpiece compared with the exit region of the wire. |
| first_indexed | 2024-03-09T16:36:30Z |
| format | Article |
| id | doaj.art-b086afea47914dff9a01f72c472a644f |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-09T16:36:30Z |
| publishDate | 2023-10-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-b086afea47914dff9a01f72c472a644f2023-11-24T14:56:04ZengMDPI AGMicromachines2072-666X2023-10-011411197610.3390/mi14111976Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process ParametersAmir Alinaghizadeh0Mohammadjafar Hadad1Bahman Azarhoushang2Department of Mechanical Engineering—Manufacturing Group, Kish International Campus, University of Tehran, Kish 1591634311, IranSchool of Mechanical Engineering, College of Engineering, University of Tehran, Tehran 1417466191, IranInstitute of Precision Machining (KSF), Hochschule Furtwangen University, 78532 Tuttlingen, GermanyForm-cutting tools are an economical choice for turning parts with defined profiles in mass production. The effects of the form contour of these tools—produced by the wire electrical discharge machining (WEDM) process—on tool quality were investigated in this research. This study focuses on reducing the adverse effects of the recast layer induced by WEDM on form-cutting tools. The basic component types of profile forms in form-cutting tools can be summarized by a combination of four modes, i.e., concave and convex arcs and flat and oblique surfaces. Hence, sample cutting tools with three different radii of convex and concave arcs and a flat surface were produced. During the WEDM operation, one-pass mode was used for roughing, two passes for semi-finishing, and three passes for finishing. Furthermore, the difference between the percentage of oxygen and carbon elements on the recast layer in the two areas above the workpiece or wire entry point and the bottom area of the workpiece or wire exit point was investigated. Finally, the influences of the direction, size of the curvature, and the number of passes in the wire electric discharge process on the recast layer were analyzed. It was observed that the recast layer thickness could be reduced by increasing the number of WEDM process. Additionally, the uniformity of the cutting contour was superior in the entry region of the wire going into the workpiece compared with the exit region of the wire.https://www.mdpi.com/2072-666X/14/11/1976form machiningwire electrical discharge machiningform-cutting toolsrecast layersurface quality |
| spellingShingle | Amir Alinaghizadeh Mohammadjafar Hadad Bahman Azarhoushang Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters Micromachines form machining wire electrical discharge machining form-cutting tools recast layer surface quality |
| title | Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters |
| title_full | Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters |
| title_fullStr | Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters |
| title_full_unstemmed | Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters |
| title_short | Experimental Study of the Surface Quality of Form-Cutting Tools Manufactured via Wire Electrical Discharge Machining Using Different Process Parameters |
| title_sort | experimental study of the surface quality of form cutting tools manufactured via wire electrical discharge machining using different process parameters |
| topic | form machining wire electrical discharge machining form-cutting tools recast layer surface quality |
| url | https://www.mdpi.com/2072-666X/14/11/1976 |
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