Effect Of Wire Tension Research Articles

Effects of non-electrical parameters on profile accuracies and surface characteristics during wire-EDM of titanium alloy

Wire lag plays a major role in causing inaccuracies in certain geometrical shapes and profiles during machining of complex structures using wire-EDM. While previous studies focused on investigating effects of electrical parameters on machining performance and accuracy during wire EDM, the effects of non-electrical parameters on corner and profile accuracies have not been studied comprehensively. The objective of this study is to investigate effects of non-electrical parameters on the geometric and profile accuracies as well as surface and subsurface characteristics during WEDM of Ti-6Al-4V alloy. A complex part including corners with 45°, 90°, and 112.5° as well as thin wall section for measuring the kerf accuracy was designed. It is found that the profile accuracy improves as the wire tension increases. However, too high wire tension results in curved path in the sharp corners. The effect of wire tension is more pronounced on the workpiece with higher thickness. Too high wire feed rate reduces the accuracy for target angles, especially for lower thickness of workpiece. The kerf width is smaller for thinner workpiece and improves with lower wire feed rate and wire tension. While the wire tension and wire feed rate do not have an impact on surface roughness, higher surface feed rate increases surface roughness. Higher wire tensions lead to higher surface cracking due to more rapid cooling. With increase of surface feed, the percentage of arcing pulses increases due to increased instability, which results in rougher surface and increased percentage of beta phases at the subsurface.

Effect of Wire Tension on Rate of Weight Bearing in Ilizarov Apparatus

Effect of Wire Tension on Rate of Weight Bearing in Ilizarov Apparatus

Effect of wire tension on different output responses during wire electric discharge machining on AISI 304 stainless steel

Abstract WEDM is used in machining conductive materials where it is required to obtained complicated and intricate shapes with high accuracy. Various applications are in the field of automobile, medical industries, aerospace etc. WEDM is an economical machining option with short product development cycle. Surface roughness, kerf width, Material removal rate, Recast layer hardness and surface microhardness in WEDM are most important responses. In this paper, effect of varied Wire tension on SR, KW, MRR, RCL hardness and surface microhardness on AISI 304 have been investigated. Pulse on time, pulse off time, current and dielectric fluid are taken as fixed parameter. Results show that Wire tension influences the SR, MRR and Surface microhardness and has no effect on kerf width in case of Stainless steel 304.

Electrical Discharge Machining of MMCs Reinforced with Very Small Particles

This paper investigates material removal rate (MRR), kerf width, surface finish, and electrode wire wear for different pule-on-times as well as wire tensions during EDM of 6061 aluminum alloy reinforced with 10 vol % 700 nm SiCp MMC. Effects of pulse-on-time on output variables at lower and higher wire tensions were investigated. Similarly, effects of the wire tensions on output variables at shorter and longer pulse-on-times were also investigated. Longer pule-on-time increases the MRR though the higher wire tension reduces the MMR. The effect of wire tension on MRR is much more significant at longer pule-on-time compare to that at shorter pule-on-time. There is an optimum pule-on-time for which best surface finish is achieved. The surface finish deteriorates when the pulse-on-time is higher or lower than the optimum pule-on-time. With the rise of tension in wire, the surface roughness increases and decreases at shorter and longer pule-on-times, respectively. The machined surface contains solidified molten material, splash of materials, and blisters. Generation of the tapered slot with higher kerf width at the top indicates the wear of wire electrode. Significant variation of the electrode wire diameter was due to coating of the matrix, wear, and clogging of small reinforced particles in the electrode gap.

Wire-Tension Effects on Plasma Dynamics in a Two-Wire $Z$ -Pinch

Heavier wire weights reduce contact resistance, which increases the energy deposition in wire plasma. Images from a two-wire Z-pinch showing the effects of wire tension on expansion performance are presented.

Effects of wire tension on the biomechanics of asymmetric four-ring circular external skeletal fixator constructs

SummaryThis study evaluated the effects of fixation wire tension (0 kg, 30 kg, 60 kg, and 90 kg) on the biomechanics of a four ring asymmetric circular external fixator construct in four testing modes (axial compression, medio-lateral bending, craniocaudal bending, and torsional loading) using a gap fracture model. Wire tension had a significant direct effect on gap stiffness in all of the testing modes. Axial compression load-deformation curves exhibited non-linearity, characteristic of the self-tensioning effect observed with fine wire fixation. Bending loaddeformation curves had two discrete linear segments, attributable to slipping of the bone models on the fixation wires, once a critical bending moment was exceeded. Torsional loading caused a gradual ‘windup’ of the construct which was followed by a linear load-displacement curve. Increasing wire tension had a small but significant effect on gap stiffness, which generally diminished as higher tensions were applied, thus demonstrating the need for adequate initial construct design to achieve sufficient stability during fracture healing.