Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts
Wire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys...
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MDPI AG
2022-12-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/1/100 |
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| author | Katerina Mouralova Josef Bednar Libor Benes Tomas Prokes Radim Zahradnicek Jiri Fries |
| author_facet | Katerina Mouralova Josef Bednar Libor Benes Tomas Prokes Radim Zahradnicek Jiri Fries |
| author_sort | Katerina Mouralova |
| collection | DOAJ |
| description | Wire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box–Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5–160 mm thicknesses, both on the surface and in the subsurface layer. |
| first_indexed | 2024-03-11T09:56:17Z |
| format | Article |
| id | doaj.art-bf942690f7e04eb58de079d061d267e4 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T09:56:17Z |
| publishDate | 2022-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-bf942690f7e04eb58de079d061d267e42023-11-16T15:46:59ZengMDPI AGMaterials1996-19442022-12-0116110010.3390/ma16010100Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold PartsKaterina Mouralova0Josef Bednar1Libor Benes2Tomas Prokes3Radim Zahradnicek4Jiri Fries5Faculty of Mechanical Engineering, Brno University of Technology, 616 69 Brno, Czech RepublicFaculty of Mechanical Engineering, Brno University of Technology, 616 69 Brno, Czech RepublicFaculty of Production Technologies and Management, Jan Evangelista Purkyně University, 400 96 Ústí nad Labem, Czech RepublicFaculty of Mechanical Engineering, Brno University of Technology, 616 69 Brno, Czech RepublicFaculty of Mechanical Engineering, Brno University of Technology, 616 69 Brno, Czech RepublicDepartment of Machine and Industrial Design, VSB - Technical University of Ostrava, 708 00 Ostrava, Czech RepublicWire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box–Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5–160 mm thicknesses, both on the surface and in the subsurface layer.https://www.mdpi.com/1996-1944/16/1/100WEDMsurface topographycutting speedAmpcoloydesign of experimentmachining parameters |
| spellingShingle | Katerina Mouralova Josef Bednar Libor Benes Tomas Prokes Radim Zahradnicek Jiri Fries Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts Materials WEDM surface topography cutting speed Ampcoloy design of experiment machining parameters |
| title | Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts |
| title_full | Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts |
| title_fullStr | Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts |
| title_full_unstemmed | Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts |
| title_short | Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts |
| title_sort | mathematical models for machining optimization of ampcoloy 35 with different thicknesses using wedm to improve the surface properties of mold parts |
| topic | WEDM surface topography cutting speed Ampcoloy design of experiment machining parameters |
| url | https://www.mdpi.com/1996-1944/16/1/100 |
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