High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM)
1
Industrial Engineering Department, College of Engineering and Architecture, Al-Yamamah University, Riyadh 11512, Saudi Arabia
2
Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, Pakistan
3
Department of Industrial Engineering, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia
4
Advanced Manufacturing Institute, College of Engineering, King Saud University, Riyadh 11421, Saudi Arabia
*
Author to whom correspondence should be addressed.
Micromachines 2021, 12(1), 1; https://doi.org/10.3390/mi12010001
Received: 24 November 2020
/
Revised: 10 December 2020
/
Accepted: 15 December 2020
/
Published: 22 December 2020
(This article belongs to the Special Issue Micro-Manufacturing and Applications)
Thin structures are often required for several engineering applications. Although thick sections are relatively easy to produce, the cutting of thin sections poses greater challenges, particularly in the case of thermal machining processes. The level of difficulty is increased if the thin sections are of larger lengths and heights. In this study, high-aspect-ratio thin structures of micrometer thickness (117–500 µm) were fabricated from D2 steel through wire electrical discharge machining. Machining conditions were kept constant, whereas the structure (fins) sizes were varied in terms of fin thickness (FT), fin height (FH), and fin length (FL). The effects of variation in FT, FH, and FL were assessed over the machining errors (FT and FL errors) and structure formation and its quality. Experiments were conducted in a phased manner (four phases) to determine the minimum possible FT and maximum possible FL that could be achieved without compromising the shape of the structure (straight and uniform cross-section). Thin structures of smaller lengths (1–2 mm long) can be fabricated easily, but, as the length exceeds 2 mm, the structure formation loses its shape integrity and the structure becomes broken, deflected, or deflected and merged at the apex point of the fins.
View Full-Text
Keywords:
wire electric discharge machining; machining; thin structures; deflection; D2 steel; fin thickness; fin length; fin height
▼
Show Figures
Figure 1
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited
MDPI and ACS Style
Ahmed, N.; Naeem, M.A.; Rehman, A.U.; Rafaqat, M.; Umer, U.; Ragab, A.E. High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM). Micromachines 2021, 12, 1. https://doi.org/10.3390/mi12010001
AMA Style
Ahmed N, Naeem MA, Rehman AU, Rafaqat M, Umer U, Ragab AE. High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM). Micromachines. 2021; 12(1):1. https://doi.org/10.3390/mi12010001
Chicago/Turabian StyleAhmed, Naveed, Muhammad A. Naeem, Ateekh U. Rehman, Madiha Rafaqat, Usama Umer, and Adham E. Ragab. 2021. "High Aspect Ratio Thin-Walled Structures in D2 Steel through Wire Electric Discharge Machining (EDM)" Micromachines 12, no. 1: 1. https://doi.org/10.3390/mi12010001
Find Other Styles
Note that from the first issue of 2016, MDPI journals use article numbers instead of page numbers. See further details here.
