Search Results (47)

Electrical discharge machining is a non-conventional shaping technique applied to electrically conductive, difficult-to-machine alloys, such as Hastelloy C-22. This study investigates the influence of graphite electrode properties and key machining parameters on the average thickness of the recast layer under positive polarity. Two POCO graphite electrodes with different grain sizes—AF-5 (1 μm) and S-180 (10 μm)—were used to examine the effects of discharge current, pulse duration, and interval on recast layer formation. Metallographic analyses measured layer thickness and observed microstructural defects, including microcracks. Results show that discharge current and pulse duration are the primary factors controlling recast layer thickness, with higher currents and longer pulses producing thicker layers due to resolidification of molten material remaining in the plasma-formed crater. The coarser S-180 electrode caused slightly higher microcrack density and greater thickness variations due to its lower electrical resistivity. Pulse interval mainly influenced discharge stability and debris removal, with minimal effect on average layer thickness. Statistical regression models were developed to quantify the relationships between machining parameters, electrode type, and recast layer thickness, providing predictive tools for selecting optimal conditions. These findings contribute to improving surface integrity and process control in electrical discharge machining of nickel-based alloys. Full article

Laser trepan drilling and laser helical drilling are typical methods for fabrication of micro through-holes through scanning laser beam. In the drilling process, the subsequent laser pulse may be occluded by the edge and the sputter deposition at the edge of the previous drilled trench. Dynamic focus feeding and widening path can be employed to lessen the occlusion effect and both of them are always employed in laser helical drilling. However, Widening the trench needs to remove more volume of material and may bring certain negative effects such as lowering the recoil pressure as well as less splashing melt due to the limited constraint of trench wall. The effects of dynamic feeding the focal plane and widening the scanning path on the quality and efficiency in the nanosecond laser drilling process were investigated through laser drilling holes with diameter of 500 μm on a 300 μm thick GH4169 plate. Results show that dynamic focus feeding is beneficial in both drilling efficiency and drilling quality. Through laser helical drilling with dynamic focus feeding, micro through-hole can be fabricated in 5 s, and both smaller tilting angle of 0.073 rad and smaller heat-affected zone of 0.63 mm in radius can be obtained. Widening scanning path is helpful to perforating rapidly but leads to much more recast layer coating. the quality of the micro through-holes depends not only on the utilization efficiency of the laser energy, but also on high temperature spatter deposition, which is the source of the difference between different drilling strategies. Due to the low cost in equipment and the better hole quality, the laser drilling, especially laser helical drilling, has potential applications ranging from aerospace fields to normal fields such as the agricultural machinery industry. Full article

Wire electrochemical discharge machining (WECDM) integrates the effectiveness of electrical discharge machining (EDM) with the superior quality of electrochemical machining (ECM), leading to enhanced machining efficiency, excellent surface finish, and significant potential for advancement. However, previous research has mainly focused on the processing of non-metallic materials, with little research in the field of the microfabrication of thick metal materials. The wire electrochemical discharge machining process with large aspect ratios is more complex. Accordingly, a unidirectional traveling wire electrochemical discharge micromachining (UWECDMM) method using a glycol-based electrolyte was proposed. The method employs a glycol solution with low conductivity and a neutral salt, facilitating enhanced mass transfer efficiency through a unidirectional traveling wire, and enabling the realization of high-efficiency, high-precision, and recast-free processing. The phenomenon of discharge in UWECDMM was observed in real-time with a high-speed camera, while the voltage and current waveforms throughout the machining process were carefully analyzed. It was found that electrolysis and discharge alternate. Experiments were conducted to investigate the wire traveling pattern, the recast layer, and the wear of the wire electrode. It was found that due to the small energy of a single discharge, the wear of wire electrodes is minimal after multiple uses and can be reused. Under optimal parameters, a machined surface without a recast layer can be obtained. In the final stages, a standard structure was machined on plates of 10 mm thickness made of pure nickel and 304 stainless steel, using a tungsten wire measuring 30 μm in diameter. The feed rate achieved was 1 μm/s, the surface roughness (Ra) measured 0.06 μm, and the absence of a recast layer confirmed the method’s sustainability and quality traits, indicating significant potential in microfabrication. Full article

This research work details the main factors affecting the orifice and profile morphology of micro-holes processed by the one-step femtosecond laser helical drilling method. Cylindrical holes or even inverted cone holes can be obtained with the appropriate deflection angle and translation distance. The orifice morphology of the micro-hole is mainly influenced by the rotation speed of the Dove prism installed inside the hollow motor, laser output power, and laser repetition frequency. A higher instantaneous power density can improve the outlet morphology and produce sharper cutting edges and thinner recast layers, although it may increase the splashing around the inlet to some extent. Subsequent to the experiment, it was determined that in order to enhance the quality of the holes, it was necessary to select a higher laser power and a lower repetition frequency, such as 10 W and 100 kHz, according to the experiments. A recast layer thickness of less than 5 µm and a surface roughness value of less than 0.8 µm were obtained within 3–5 s processing time, which can satisfy the requirements for aircraft application of efficiency and quality. Full article

As a hard and brittle material, the processing of C_f/SiC ceramic matrix composites (CMCs) faces significant challenges, especially in the processing of small-sized shapes. To address this challenge, laser processing with gas-assisted nanosecond laser (GNL) and waterjet-guided nanosecond laser (WNL) modes were applied to fabricate thin kerfs in the C_f/SiC composite. The surface morphology, microstructure, and chemical composition of the processed C_f/SiC composite were investigated comparatively. The results revealed that the coupling of helium in the GNL mode laser processing could make full use of the laser energy, but resulted in spattering in the kerf margin and a recast layer in the kerf surface, accompanied by obvious oxidation, while the coupling of the waterjet in the WNL mode laser processing decreased the oxidation significantly and removed the remelting debris, which produced a clear and flat kerf surface. Due to the taper caused by laser energy dissipation, the single-path laser processing in the C_f/SiC composite had a limited depth. The maximum depth of the kerf prepared by single-path laser processing with the GNL mode was about 328 μm, while that with the WNL mode was about 302 μm. The multi-path laser processing with the GNL and WNL modes could fabricate a through kerf in the C_f/SiC composite, but the coupling medium obviously influenced the surface morphology and microstructure of the underlying region. The kerf surface prepared by the GNL mode had a varied surface morphology, which transited from the top layer, covered with oxide particles and some cracks, to the bottom layer, featured with micro-grooves and small oxides. The kerf surface prepared by the WNL mode had a consistently smooth and clean morphology featured with broken carbon fiber and residual SiC matrix. The slow laser energy dissipation and open environment in the GNL mode resulted in a bigger HAZ and relatively serious oxidation, which caused local phase transformation and microstructure degradation. The isolation condition and rapid cooling in the WNL mode decreased the HAZ and restrained the oxidation, almost keeping the original microstructure. The thicknesses of the HAZ in the GNL- and WNL-processed C_f/SiC composite were about 200 μm and 100 μm, respectively. The WNL-processed C_f/SiC composite had a lower oxidation and thermal damage surface, which is instructive for the processing of the C_f/SiC composite. Full article

Since one of the effective methods for producing the form-cutting tools used in the form-turning process involves utilizing a wire cut machine, the effect of the geometric characteristics of the form contour on reducing the negative effects of the recast layer was investigated in this research. The basic assumption of the components for each type of profile form is based on a combination of four modes, i.e., concave arc, convex arc, flat surface, and oblique surface. Based on this, samples were fabricated as cutting tools with three different radii: a convex arc, a concave arc, and a flat surface. During the wire electrical discharge machining (WEDM) operation, one-pass mode was used to create a rough surface, two passes resulted in a semi-finished surface, and three passes resulted in a finished surface. Furthermore, the difference between the surface quality of the recast layer in the two areas above the workpiece or the wire entry point and the bottom area of the workpiece or the wire exit point was studied. Finally, the effect of the direction, size of the curvature and the number of passes in the electric discharge process of the wire on the recast layer was shown, and it was observed that with the increase in the number of passes in WEDM, the thickness of the recast layer was reduced, along with the uniformity of the cutting contour section in the areas close to the cutting region. The entry of the wire was greater than that in the areas near the exit of the wire. Full article

This study investigates a novel short electric arc vertical turning method for machining titanium alloy shafts. The method was successfully applied to titanium alloy rods, and its effects on material removal rate (MRR), surface roughness, roundness, and cross-sectional morphology were analyzed at varying processing voltages. The results indicate that the MRR and surface quality improve with increased voltage, reaching a maximum of 231 mm³/min and 26 μm surface roughness at 32 V. However, surface roughness deteriorates with higher duty cycles and voltages due to unstable discharges. Roundness deviations are minimized with higher rotational speeds, which enhance uniform material removal and arc stability. Metallographic analysis revealed an increased heat-affected zone and recast layer thickness at higher voltages. This method demonstrates high machining efficiency and improved surface quality, making it suitable for titanium alloy shaft manufacturing in advanced engineering applications. Full article

C_f-UHTC is an ideal aerospace material because of its exceptional properties, but its machinability is facing great challenges. Electrical discharge machining (EDM) offers a potential solution, but its removal mechanism remains unclear, lacking reliable prediction tools to guide the actual production. This paper deeply explores the EDM removal mechanism of C_f-ZrB₂-SiC through single-pulse experiments, high-speed camera observations, and thermal–fluid coupling simulations, revealing key processes like heat transfer, phase transformation, molten pool dynamics, crater formation, and reinforcing phase effects. And the prediction of single-pulse removal with different parameters is also realized. Based on experimental and simulation results, a random continuous discharge model is developed, which deeply studies the dynamic erosion process, reconstructs EDM surfaces, and accurately predicts surface roughness. Furthermore, the thickness of the recast layer can be predicted based on the equivalent temperature method. Undoubtedly, this model provides an ideal approach for efficient production. Full article

The presented article is about the axisymmetric deformation of an annular one-dimensional hexagonal piezoelectric quasicrystal actuator/sensor with different configurations, analyzed by the three-dimensional theory of piezoelectricity coupled with phonon and phason fields. The state space method is utilized to recast the basic equations of one-dimensional hexagonal piezoelectric quasicrystals into the transfer matrix form, and the state space equations of a laminated annular piezoelectric quasicrystal actuator/sensor are obtained. By virtue of the finite Hankel transform, the ordinary differential equations with constant coefficients for an annular quasicrystal actuator/sensor with a generalized elastic simple support boundary condition are derived. Subsequently, the propagator matrix method and inverse Hankel transform are used together to achieve the exact axisymmetric solution for the annular one-dimensional hexagonal piezoelectric quasicrystal actuator/sensor. Numerical illustrations are presented to investigate the influences of the thickness-to-span ratio on a single-layer annular piezoelectric quasicrystal actuator/sensor subjected to different top surface loads, and the effect of material parameters is also presented. Afterward, the present model is applied to compare the performance of different piezoelectric quasicrystal actuator/sensor configurations: the quasicrystal multilayer, quasicrystal unimorph, and quasicrystal bimorph. Full article

Die-sink electric discharge machining (EDM) is essential for shaping complex geometries in hard-to-machine materials. This study aimed to optimize key input parameters, such as the discharge current, gap voltage, pulse-on time, and pulse-off time, to enhance the EDM performance by maximizing the material removal rate while minimizing the surface roughness, residual stress, microhardness, and recast layer thickness. AISI 316L stainless steel was chosen due to its industrial relevance and machining challenges, while a Ti-6Al-4V-SiCp composite electrode was selected for its thermal resistance and low wear. Using Taguchi’s L₂₇ orthogonal array, this study minimized the trial numbers, with analysis of the variance-quantifying parameter contributions. The results showed a maximum material removal rate of 0.405 g/min and minimal values for the surface roughness (1.95 µm), residual stress (1063.74 MPa), microhardness (244.8 Hv), and recast layer thickness (0.47 µm). A second-order model, developed through a response surface methodology, and a feed-forward artificial neural network enhanced the prediction accuracy. Multi-response optimization using desirability function analysis yielded an optimal set of conditions: discharge current of 5.78 amperes, gap voltage of 90 volts, pulse-on time of 100 microseconds, and pulse-off time of 15 microseconds. This setup achieved a material removal rate of 0.13 g/min, with reduced surface roughness (2.46 µm), residual stress (1518.46 MPa), microhardness (259.01 Hv), and recast layer thickness (0.87 µm). Scanning electron microscopy further analyzed the surface morphology and recast layer characteristics, providing insights into the material behavior under EDM. These findings enhance the understanding and optimization of the EDM processes for challenging materials, offering valuable guidance for future research and industrial use. Full article

The water-assisted laser trepanning method has been proven to improve the quality of laser drilling; however, the effect of water temperature on this process is currently unclear. In order to investigate the influence of water temperature on the quality of holes produced via water-assisted laser trepanning in superalloys, this study used the controlled variable method to investigate the effects of three water temperatures—low temperature (2 °C), normal temperature (20 °C), and high temperature (70 °C)—on the following factors: spatter, hole diameter, taper angle, hole sidewall morphology, and recast layer. The results show that the spatter around the hole reduced, the hole entrance/exit diameter increased, and the roughness of the hole’s sidewall decreased with an increase in single-pulse energy. However, the effect of single-pulse energy on the recast layer was not obvious. As the temperature of the water increased, the hole entrance/exit diameter increased, and the roughness of the hole’s sidewall decreased. When the single-pulse energy was 1.0–1.9 J, using a lower water temperature produced a hole with a smaller taper angle. Compared with a water temperature of 20 °C, the movement of the melt film on the hole’s sidewall accelerated when the water temperature was 70 °C; as a result, more molten material could be removed from the hole, resulting in a decrease in the thickness of the recast layer. However, when the water temperature was 2 °C, the heat-affected zone and the thickness of the recast layer decreased more significantly. The results of this study provide technical support for the optimization of water-assisted laser drilling. Full article

Tungsten carbide (WC) and its composites are typically associated with high hardness and high wear resistance, posing challenges in conventional machining processes like turning. To address the machining difficulties of WC-Co, electrical discharge turning (EDT) was proposed. The rotational speed in EDT is a key factor influencing the machining results; however, conflicting reports exist about its impact on the EDT process. Therefore, the effect of rotational speed on three different machining regimes, including roughing, semi-finishing, and finishing, was investigated using energy-dispersive X-ray spectroscopy (EDX), SEM, and roughness tests. Additionally, elemental mapping was applied to illustrate the element distribution on the machined surface. The results indicated that increasing the rotational speed led to a 10% to 17% decrease in the recast layer thickness and a 14% to 54% reduction in the surface roughness (Ra). Full article

Network microstructure titanium matrix composites (NMTMCs), featuring Ti6Al4V as the matrix and network-distributed TiB whiskers (TiBw) as reinforcement, exhibit remarkable potential for diverse applications due to their superior physical properties. Due to the difficulty in machining titanium matrix composites, electrical discharge machining (EDM) stands as one of the preferred machining techniques for NMTMCs. Nevertheless, the compromised surface quality and the recast layer significantly impact the performance of the workpiece machined by EDM. Therefore, for the purpose of enhancing the surface quality and restraining the defects of NMTMCs, this study conducted comparative EDM milling experiments between NMTMCs and Ti6Al4V to analyze the effects of discharge capacitance, charging current, and pulse interval on the surface roughness, recast layer thickness, recast layer uniformity, and surface microcrack density of both materials. The results indicated that machining energy significantly influences workpiece surface quality. Furthermore, comparative experiments exploring the influence of network reinforcement on EDM milling revealed that NMTMCs have a higher melting point, leading to an accumulation phenomenon in low-energy machining where the reinforcement could not be completely removed. The residual reinforcement in the recasting layer had an adsorption effect on molten metal affecting the thermal conductivity and uniformity within the recasting layer. Finally, specific guidelines are put forward for optimizing the material’s surface roughness, recast layer thickness, and uniformity, along with minimizing microcrack density, which attain a processing effect that features a roughness of Ra 0.9 μm, an average recast layer thickness of 6 μm with a range of 8 μm, and a surface microcrack density of 0.08 μm⁻¹. Full article

The use of static solution-assisted laser drilling can effectively improve hole roundness, decrease taper angle, and reduce recast layer thickness and hole wall slag adhesion. However, the enormous energy of the laser will evaporate the solution to form a suspension droplet and reduce the quality and efficiency of laser drilling. To deal with this defect, the mist-blowing method was used to reduce the influence of droplets on the taper angle and recast layer. In this work, the effect of wind speed on drilling quality was examined, and laser drilling in air, water, and NaCl solution was carried out to analyse the effect of solution composition on hole wall morphology. The results showed that a speed fan with a proper wind speed that disperses the droplets formed in the processing area can significantly reduce the refraction and scattering of the laser, and the taper angle and roundness of the drilling hole were also reduced by 15.6% and improved by 2.4%, respectively, under the wind speed of 2 m/s. The hole wall morphology showed a thicker recast layer and cracking in air, while it was thinner in water and there was little or no layer in the NaCl solution in the same current. When drilling in NaCl, the taper angle and roundness of the drilling hole were reduced by 4.13% and improved by 2.11%, respectively, compared to water. Due to the mechanical effect of the laser in the NaCl solution, the impact force on the material was much greater than that in water. The solution cavitation effect, generated by the absorption of laser energy, caused an explosive impact on the molten material adhered to the surface of the hole wall. Above all, drilling in the NaCl solution with a current of 200 A and a wind speed of 2 m/s was the optimal condition for obtaining the best processing quality. Full article

In comparison to conventional EDM, micro EDM distinguishes itself through its brief discharge duration, narrow discharge channel radius, and concentrated energy density. However, there remains a paucity of comprehensive research on the surface formation characteristics in this domain. This paper delves into the formation mechanism of the recast layer in micro EDM workpieces, scrutinizing the primary factors that influence the formation process and the morphological attributes of the recast layer. We conducted a series of single-pulse experiments and micro EDM trials. Utilizing surface fitting tools, our experimental findings facilitated the derivation of a relational expression between the recast layer thickness of high-speed steel and the discharge parameters in micro EDM. Notably, when the energy is below 100 μJ, the recast layer thickness remains under 10 μm. Specifically, at an energy level of 16 μJ, opting for a smaller capacitance of 2200 pf and a higher voltage of 120 V in micro EDM results in a thinner recast layer. This study serves as a cornerstone for future efforts aimed at controlling and assessing the surface morphology of micro EDM. Full article