Sustainable production of high-uniformity workpiece surface quality in wire electrical discharge machining by fabricating surface microstructure on wire electrode
Sustainable production of high-uniformity workpiece surface quality in wire electrical discharge machining by fabricating surface microstructure on wire electrode
复制标题
通过在线电极上制造表面微结构，在线放电加工中可持续生产高均匀性工件表面质量
DOI：
10.1016/j.jclepro.2020.120881
复制
发表时间：
2020-06
影响因子：
11.1
通讯作者：
Chen Zhi
中科院分区：
文献类型：
--
作者：
Yan Hongzhi;Kabongo Djo Bakadiasa;Yan Zhaojun;Han Fenglin;Chen Zhi
传统的线电极在线放电加工（WEDM）时，工件沿厚度方向的表面质量总是不均匀，这对工件的可用性和可靠性产生重大影响。为了解决这个问题，本文旨在提出一种在线电极上制造表面微结构（SMWE）的新方法，以可持续生产高均匀性工件表面质量。首先，对采用镀锌丝电极（ZCWE）时工件表面质量均匀性进行了实验研究。可以发现，中部区域的表面粗糙度（Ra）和表面质量最差，其次是顶部区域和底部区域。拉氏均匀度可达0.44。此外，还介绍了SMWE的生产工艺，包括铸造、涂层、退火和塑性加工。电极丝表面微观结构的形成机理是基于涂层的热膨胀系数低于线芯的热膨胀系数。然后，与ZCWE相比，分析了SMWE在放电特性和工件表面质量均匀性方面的改进。可以看出，SWEM可以提高点放电的概率和正常放电状态的比例。此外，SMWE可使表面粗糙度平均值降低17.3%~22.2%，表面粗糙度均匀度提高9.5%~52.1%。即，所提出的SMWE对于可持续生产高均匀性工件表面质量是可行的。最后还分析了工艺参数对表面粗糙度均匀性的影响。可以发现，小放电峰值电流、短脉冲开启时间、长脉冲关闭时间、高间隙参考电压和适当的走丝速度对于高均匀性表面质量是推荐的。
When the traditional wire electrode is used in wire electrical discharge machining (WEDM), the workpiece surface quality along thickness direction is always nonuniform which has a significant impact to the usability and reliability of workpiece. To address this issue, this paper aims to propose a new method of fabricating surface microstructure on wire electrode (SMWE) for sustainable production of high-uniformity workpiece surface quality. Firstly, an experimental research of workpiece surface quality uniformity is implemented when zinc coated wire electrode (ZCWE) is used. It can be found that the surface roughness (Ra) and surface quality on the middle area are the worst followed by the top area and bottom area. The uniformity ofRacan be up to 0.44. Additionally, the production process of SMWE is described which includes casting, coating, annealing and plastic processing. The forming mechanism of surface microstructure on wire electrode is based on the thermal expansion coefficient of coating layer is lower than that of wire core. And then, compared with ZCWE, the improvements of SMWE on the discharge characteristic and workpiece surface quality uniformity are analyzed. It can be obtained that SWEM can increase the probability of point discharge and the ratio of normal discharge status. Besides, SMWE can reduce the mean value of surface roughness by 17.3%–22.2% and increase the uniformity of surface roughness by 9.5%–52.1%. Namely, the proposed SMWE for sustainable production of high-uniformity workpiece surface quality is feasible. Eventually, the effects of process parameters on the uniformity of surface roughness are also analyzed. It can be found that small discharge peak current, short pulse on time, long pulse off time, high gap reference voltage and appropriate wire speed are recommended for high-uniformity surface quality.
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影响因子：
6.2
作者：
Sharma, Priyaranjan;Chakradhar, D.;Narendranath, S.
通讯作者：
Narendranath, S.
影响因子：
5.6
作者：
H. Majumder;K. Maity
通讯作者：
H. Majumder;K. Maity
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DOI：
10.1007/s00170-016-8784-0
发表时间：
2016-04
影响因子：
3.4
作者：
Gong Yadong;Sun Yao;Wen Xuelong;Wang Chao;Gao Qi
通讯作者：
Gao Qi
影响因子：
7.3
作者：
Zhi Chen;Guojun Zhang;Han Fenglin;Yanming Zhang;Y. Rong
通讯作者：
Zhi Chen;Guojun Zhang;Han Fenglin;Yanming Zhang;Y. Rong
影响因子：
6.2
作者：
R. Soundararajan;A. Ramesh;N. Mohanraj;N. Parthasarathi
通讯作者：
R. Soundararajan;A. Ramesh;N. Mohanraj;N. Parthasarathi