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Reduction of Energy Consumption and Thermal Deformation in WEDM by Magnetic Field Assisted Technology

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International Journal of Precision Engineering and Manufacturing-Green Technology Aims and scope Submit manuscript

Abstract

Energy consumption and machining accuracy are considered to be two important attributes of performance indicators for green operations of wire electric discharge machining (WEDM). However, there is a paucity of studies that focus on the energy consumption and geometric error caused by thermal deformation. In this paper, a hybrid technique of WEDM with assisted magnetic field (MF) is proposed for enhancing machining performance to reduce energy consumption and thermal deformation. Based on the principles of thermal deformation, energy consumption, and magnetic field-assisted WEDM, a set of experiments is conducted to investigate thermal deformation and energy consumption of MF-assisted WEDM and conventional WEDM machining of Inconel 718. The effects of magnetic field on thermal deformation, discharge waveforms, surface integrity, and energy consumption are analyzed, and it is concluded that the proposed hybrid technique of MF-assisted WEDM offers numerous advantages and potential for applications in the green precision manufacturing field.

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Abbreviations

\({\text{d}}\epsilon_{e}\) :

Increment of elastic strain

\(d\epsilon_{p}\) :

Increment of plastic strain

\(d\epsilon_{t}\) :

Increment of thermal strain

σ :

Stress increment

\(\epsilon\) :

Strain increment

D ep :

Elastic–plastic stress–strain matrix

D e :

Elastic stress–strain relation matrix

B :

Geometric matrix

E :

The consumed energy

V :

Volume of the removed material

I :

Current

U :

Voltage of spark gab

T on :

Pulse-on time

v c :

Average feed rate

H :

Workpiece thickness

\(F_{\alpha }\) :

Ampere force

L :

The length of wire electrode locating at the magnetic field

\(B_{\alpha }\) :

Magnetic field density

F t :

Electromagnetic force

J e :

The externally generated current density

D :

Bending degree

t :

Beam thickness

d :

Beam deflection

k :

Cutting width

T off :

Pulse-off time

WP :

Water pressure

WS :

Wire speed

MFI :

Magnetic field intensity

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Acknowledgements

This research is supported by National Natural Science Foundation of China (NSFC) under Grant No. 51705171, Pre-research Area Funds of “13th Five-Year Plan” Equipment under Grant No. 6140923030401, and Guangdong HUST Industrial Technology Research Institute, Guangdong Provincial Key Laboratory of Digital Manufacturing Equipment (2017B030314146).

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Authors and Affiliations

  1. School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Yanming Zhang, Guojun Zhang & Wenyuan Li

  2. State Key Lab of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Yanming Zhang, Guojun Zhang & Wenyuan Li

  3. School of Aerospace Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Zhen Zhang

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  1. Yanming Zhang
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Zhang, Y., Zhang, Z., Zhang, G. et al. Reduction of Energy Consumption and Thermal Deformation in WEDM by Magnetic Field Assisted Technology. Int. J. of Precis. Eng. and Manuf.-Green Tech. 7, 391–404 (2020). https://doi.org/10.1007/s40684-019-00086-5

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