Abstract
This paper describes results of experimental research on the thin microhardened surface layer of a machined surface that occurs in materials using wire electrical discharge machining (WEDM) with brass wire electrode. The direct influence of microhardened surface layer on resulting machined surface quality of tool steel EN X210Cr12 (W.-Nr. 1.2080) was examined. The aim of the experiment was to contribute to the knowledge of mutual interactions between main WEDM technological parameters, the influence of these parameters on the total affected depth, and on the variation of microhardness of sub-surface layers of machined surface. Based on the microhardness experimental measurements, mathematical models were established by the Least Square Method (LSM) in order to simulate and predict final quality of machined surface after WEDM. Recommendations are given for setting the main technological parameters of the discharge process concerning minimization of total microhardened surface layer depth and microhardened surface layer homogeneity along the whole cross-section profile of the machined surface.
Highlights
Achievable qualitative parameters of eroded surface are comparable to the parameters achieved by finishing machining technologies [1,2] such as grinding, honing, lapping, superfinishing, etc
The objectives of the experiment were to carry out detailed research of the thin microhardened surface layer of machined surface at wire electrical discharge cutting of steel EN X210Cr12 (W.-Nr.1.2080) with brass Ms63 wire electrode of 0.25 mm diameter; to evaluate consequences of heat affected zone (HAZ) on final quality of machined surface; and to contribute to the knowledge database of HAZ at electrical discharge process
Mathematical models were implemented into a simulation program, which enabled specifying an optimal combination of main technological parameters with focus on the required value of the hHAZ parameter
Summary
Achievable qualitative parameters of eroded surface are comparable to the parameters achieved by finishing machining technologies [1,2] such as grinding, honing, lapping, superfinishing, etc. A complex evaluation of machined surface quality after WEDM is a demanding procedure. Quality judgments based only on selected parameters—most often these are roughness parameters Ra, Rz, and Ry—can lead to subjective evaluation or even mistakes [4]. The character and surface quality, from the aspect of heat treatment, have considerably greater impact on machined surface quality than the roughness itself [5]. [6] In this sense, significant quality indicators are parameters that characterize the heat-affected zone—its total depth [7], structure [8,9], homogeneity, hardness variation, and hardness course [10] Durability and functionality of the surface primarily pre-define its suitable heat treatment or thermo-mechanical treatment. [6] In this sense, significant quality indicators are parameters that characterize the heat-affected zone—its total depth [7], structure [8,9], homogeneity, hardness variation, and hardness course [10]
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