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Erschienen in: The International Journal of Advanced Manufacturing Technology 11-12/2020

28.01.2020 | ORIGINAL ARTICLE

Attainment of high corner accuracy for thin-walled sharp-corner part by WEDM based on magnetic field-assisted method and parameter optimization

verfasst von: Hongzhi Yan, Kabongo Djo Bakadiasa, Zhi Chen, Zhaojun Yan, Hongbing Zhou, Fenglin Han

Erschienen in: The International Journal of Advanced Manufacturing Technology | Ausgabe 11-12/2020

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Abstract

The demand for thin-walled sharp-corner parts is constantly becoming higher in aerospace, precise instruments, and micro-electro-mechanical systems (MEMS). Nonetheless, the fabrication of thin-walled sharp-corner part is a challenging work because of its poor stiffness. Wire electrical discharge machining (WEDM) is an alternative method to machine low-stiffness part due to its non-contact material removal process. However, experimental data show that there exists an inevitable deformation in the corner area of thin-walled sharp-corner part. The goal of this paper is to achieve high corner accuracy for thin-walled sharp-corner part based on magnetic-assisted approach and parameter optimization. Firstly, a coupled magnetic-mechanical model is established to analyze the effect of the external magnetic field on the corner deformation. It can be found that the external magnetic field can effectively improve the magnetic field distribution and decrease the corner deformation. There is optimal external magnetic induction intensity between 0.2 and 0.3 T for smaller corner deformation. Then, the results of verification experiment indicate that the coupled magnetic-mechanical model is of high feasibility and reliability. In addition, a set of Taguchi experiment is implemented to investigate the influences of process parameters on the corner deformation. It can be obtained that corner deformation rises up with the increase of pulse on time and discharge peak current, and reduces along with pulse-off time. Furthermore, the optimal process parameter combination from the range analysis method can reduce corner deformation from 100 to 34.3 μm.

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Metadaten
Titel
Attainment of high corner accuracy for thin-walled sharp-corner part by WEDM based on magnetic field-assisted method and parameter optimization
verfasst von
Hongzhi Yan
Kabongo Djo Bakadiasa
Zhi Chen
Zhaojun Yan
Hongbing Zhou
Fenglin Han
Publikationsdatum
28.01.2020
Verlag
Springer London
Erschienen in
The International Journal of Advanced Manufacturing Technology / Ausgabe 11-12/2020
Print ISSN: 0268-3768
Elektronische ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-020-04966-y

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