The Effects of Using Brass and Copper Wires on the Cutting Quality of Sleipner Cold Work Steel Cut by WEDM

Year 2022, , 163 - 178, 18.12.2022

Ferhat Ceritbinmez , Erdoğan Kanca

https://doi.org/10.55546/jmm.1117441

Cited By: 1

Abstract

Wire electric discharge machining (WEDM) is widely used in dies, punches, aerospace and automotive sectors, since materials with high hardness, and temperature resistant, which are not possible to be cut with conventional machining methods, can be cut with high precision using the WEDM method. In this study, cutting speed (mm/min), material removal rate (mm3/min), wire consume (g), machining time (sec), finish measure (mm) and surface roughness (µm) changes as a result of cutting high hardness cold work tool steel using copper and brass wire in WEDM method were investigated. In addition, worn wire and workpiece residues on the machined surfaces were detected by SEM (Scanning Electron Microscope) and EDX (Energy Dispersive X-Ray) analyzes as well as topography and composition were examined. In the case of using copper wire instead of the brass wire, wire consumption and processing time decreased by 23.30 % and 66.29 %, respectively, while MRR increased by 50 % because the copper wire electrode has higher electrical and thermal conductivity than brass wire electrode. In addition, the average dimensional deviation of the parts cut with copper wire decreased from 27 μm to 8 μm compared to the use of brass electrodes, and more precise measurements were obtained.

Keywords

WEDM, Stell, Wear, Surface Roughness, Material Removal Rate

Thanks

We would like to thank the Haier Europe, Candy-Hoover tool shop employees who supported the operation of the Charmilles Robofil 290P WEDM machine used in this study.

WEDM ile Kesilen Sleipner Soğuk İş Çeliğinin Kesim Kalitesine Pirinç ve Bakır Tel Kullanımının Etkileri

Abstract

Geleneksel işleme yöntemleriyle kesilmesi mümkün olmayan yüksek sertlik ve sıcaklığa dayanıklı malzemeler tel elektrik deşarjlı işleme (WEDM) yönteminde yüksek hassasiyetle kesilebildiğinden; bu yöntem kalıp, zımba, havacılık ve otomotiv sektörlerinde yaygın olarak kullanılmaktadır. Bu çalışmada, yüksek sertliğe sahip soğuk iş takım çeliğinin WEDM yönteminde bakır ve pirinç teller ile kesilmesi neticesinde elde edilen kesme hızı (mm/dak), talaş kaldırma oranı (mm3/dak), tel tüketimi (g), işleme zamanı (sn), bitiş ölçüsü (mm), yüzey pürüzlüğü (µm) değişimi incelenmiştir. Ayrıca SEM (Taramalı Elektron Mikroskobu) ve EDX (Energy Dispersive X-Ray) analizleri ile işlenen yüzeylerde aşınmış tel ve iş parçası kalıntıları tespit edilerek topografya ve kompozisyon incelenmiştir. Pirinç tel yerine bakır tel kullanılması durumunda tel tüketimi ve işlem süresi sırasıyla % 23.30 ve % 66.29 azalırken, bakır tel elektrot pirinç tel elektrota göre daha yüksek elektriksel ve ısıl iletkenliğe sahip olduğundan talaş kaldırma oranı % 50 artmıştır. Ayrıca bakır tel ile kesilen parçaların ortalama ölçüsel sapması pirinç elektrot kullanımına göre 27 μm'den 8 μm'ye düşmüş ve daha yüksek ölçüsel hassasiyet elde edilmiştir.

Keywords

Çelik, Aşınma, Yüzey Pürüzlüğü, Talaş Kaldırma Oranı, WEDM

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