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Modeling of kerf width and surface roughness in wire cut electric discharge machining of Ti-6Al-4V
Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering ( IF 2.4 ) Pub Date : 2020-06-19 , DOI: 10.1177/0954408920932369
K Venkata Rao 1 , L Ratna Raju 1 , Chiluka Kiran Kumar 2
Affiliation  

Surface roughness and kerf width are the two challenging quality characteristics in wire cut electric discharge machining (WEDM) of Ti-6Al-4V to improve accuracy in machining. In this study, effect of wire displacement on the kerf width and surface roughness is studied in WEDM of Ti-6Al-4V. Mechanistic models are developed for kerf width and surface roughness using amplitude and frequency of wire vibration in X and Y directions. Amplitude and frequency of wire displacement in X and Y directions are directly measured using an accelerometer at different working conditions. The estimated kerf width and surface roughness are compared with the experimental results and the average error between them is found to be 3.7 and 4.2% respectively. The results showed that the current and wire tension have significant effect on the wire displacement. The kerf width and surface roughness are effected more by the applied current and the metal removal rate is effected by current and pulse on time. A working condition with 3.3 A of current, 15 N of wire tension, 14.4 µs of pulse on time and 41.5 µs of pulse off time is found to be an optimum working condition.

中文翻译:

Ti-6Al-4V线切割电火花加工切口宽度和表面粗糙度建模

表面粗糙度和切口宽度是 Ti-6Al-4V 线切割放电加工 (WEDM) 中两个具有挑战性的质量特性,可提高加工精度。在这项研究中,在 Ti-6Al-4V 的 WEDM 中研究了线位移对切口宽度和表面粗糙度的影响。使用 X 和 Y 方向线振动的幅度和频率,针对切口宽度和表面粗糙度开发了机械模型。在不同的工作条件下,使用加速度计直接测量 X 和 Y 方向的线位移的幅度和频率。将估计的切口宽度和表面粗糙度与实验结果进行比较,发现它们之间的平均误差分别为 3.7% 和 4.2%。结果表明,电流和线张力对线位移有显着影响。切口宽度和表面粗糙度受施加电流的影响更大,金属去除率受电流和脉冲准时的影响。发现具有 3.3 A 电流、15 N 线张力、14.4 µs 脉冲开启时间和 41.5 µs 脉冲关闭时间的工作条件是最佳工作条件。
更新日期:2020-06-19
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