The effect of material grain structure on the surface integrity of components processed by microwire electrical discharge machining (μWEDM)

Andrew Rees, Stefan Dimov, Roussi Minev, Georgi Lalev, Andrzej Rosochowski, Lech Olejnik

Research output: Contribution to journalArticle

Abstract

The machining response of metallurgically and mechanically modified materials
when processed by employing the microwire electrical discharge machining (µWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5000 series aluminium alloys after µWEDM processing is studied. The machining response of an ‘as received’ aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process–material effects on the resulting microhardness, phase content changes, heat-affected zone, surface roughness, microcracks, recast layer, material removal rate, and element spectrum after both rough and finishing µWEDM cuts were investigated. This study shows that an ultrafine grained (UFG) Al5083 exhibits not only superior mechanical properties but also the machining response to µWEDM is favourable. A reduction of the recast layer after WEDM was observed when compared with ‘as received’ and ‘conventionally’ processed Al5083.
LanguageEnglish
Pages1647-1656
Number of pages10
JournalProceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
Volume225
Issue number9
DOIs
Publication statusPublished - 1 Sep 2011

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Electric discharge machining
Crystal microstructure
Machining
Aluminum alloys
Microcracks
Heat affected zone
Strain hardening
Microhardness
Extrusion
Plastic deformation
Surface roughness
Mechanical properties
Microstructure
Processing

Keywords

  • µWEDM
  • surface integrity
  • UFG material

Cite this

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abstract = "The machining response of metallurgically and mechanically modified materialswhen processed by employing the microwire electrical discharge machining (µWEDM) technology is reported in this paper. In particular, the effects of the material microstructure on resulting surface integrity of Al5000 series aluminium alloys after µWEDM processing is studied. The machining response of an ‘as received’ aluminium alloy was compared against the results obtained on samples processed through extrusion strain hardening and severe plastic deformation. Especially, the process–material effects on the resulting microhardness, phase content changes, heat-affected zone, surface roughness, microcracks, recast layer, material removal rate, and element spectrum after both rough and finishing µWEDM cuts were investigated. This study shows that an ultrafine grained (UFG) Al5083 exhibits not only superior mechanical properties but also the machining response to µWEDM is favourable. A reduction of the recast layer after WEDM was observed when compared with ‘as received’ and ‘conventionally’ processed Al5083.",
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The effect of material grain structure on the surface integrity of components processed by microwire electrical discharge machining (μWEDM). / Rees, Andrew; Dimov, Stefan; Minev, Roussi; Lalev, Georgi; Rosochowski, Andrzej; Olejnik, Lech.

In: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 225, No. 9, 01.09.2011, p. 1647-1656.

Research output: Contribution to journalArticle

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