WEDM-Cut NiCrMo: A Comparison of Copper and Brass Wires

Abstract

WEDM (Wire Electrical Discharge Machining) is an advanced manufacturing method based on the principle of chip removal by creating high-frequency electrical sparks between the workpiece and the wire electrode. In this method, the wire electrode does not come into contact with the workpiece; instead, electrical discharge occurs through a very small gap. This method offers contactless processing, high precision and smoothness, control of thermal effects, complex geometry cuts, and the ability to process hard materials with tight tolerances, making it possible to easily process materials such as super alloys, carbides, titanium, Inconel, and NiCrMo. In this study, the cutting of NiCrMo alloy, which is difficult to process due to its high strength and low thermal conductivity, using copper and brass wire electrodes in the WEDM method was investigated. SEM (Scanning Electron Microscope) and EDX (Energy Dispersive X-Ray) analyses of the cut surfaces revealed the formation of micro cracks, voids, globules, craters, and debris on the processed surfaces, as well as electrode residues such as Cu and Zn. It was observed that the average surface roughness values of the surfaces cut using copper and brass wire electrodes were 2.331 µm and 3.919 µm Ra, respectively. It has been determined that copper wire is 40.52% more efficient than brass wire electrodes due to its high conductivity, good thermal diffusion and more stable discharges.

Keywords

• WEDM
• NiCrMo
• Copper
• Brass
• Surface Roughness

WEDM ile Kesilmiş NiCrMo: Bakır ve Pirinç Tellerin Karşılaştırılması

Abstract

WEDM (Tel Elektrik Deşarj İşleme) işlenecek parça ile tel elektrot arasında yüksek frekanslı elektriksel kıvılcımlar oluşturularak talaş kaldırma prensibine dayanan ileri imalat yöntemidir. Bu yöntemde tel elektrot iş parçasına temas etmez sadece çok küçük bir boşluk üzerinden elektriksel boşalma gerçekleşir. Bu yöntemin sahip olduğu temassız işleme, yüksek hassasiyet ve pürüzsüzlük, ısıl etkilerin kontrolü, karmaşık geometri kesimleri, dar toleranslarda ve sert malzemeleri işleyebilme özelliklerinden dolayı süper alaşımlar, karbürler, titanyum, inconel, NiCrMo gibi malzemelerin kolayca işlenebilmesine olanak sağlamaktadır. Bu çalışmada yüksek mukavemet ve düşük ısıl iletkenlik nedeniyle zor işlenebilir sınıfında olan NiCrMo alaşımının WEDM yönteminde bakır ve pirinç tel elektrot ile kesilmesi araştırılmıştır. Kesilen yüzeylerin (SEM) Taramali Elektron Mikroskobu ve (EDX) Enerji Dağılımlı X-ışını Spektroskopisi analizleri neticesinde işlenmiş yüzeylerde mikro çatlaklar, oyuklar, kabarcıklar, kraterler ve döküntü oluşumunun yanı sıra Cu ve Zn gibi elektrot kalıntıları tespit edilmiştir. Bakır ve pirinç tel elektrot kullanılarak kesilen yüzeylerin sırası ile ortalama 2,331 µm ve 3,919 µm Ra yüzey pürüzlülük değerlerinde olduğu görülmüştür. Bakır tel’in yüksek iletkenlik, iyi ısıl yayılımı ve daha kararlı deşarjları sayesinde pirinç tel elektrota göre % 40,52 daha performanslı olduğu tespit edilmiştir.

Keywords

• WEDM
• NiCrMo
• Bakır
• Pirinç
• Yüzey Pürüzlüğü

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