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The International Journal of Advanced Manufacturing Technology
Published in: The International Journal of Advanced Manufacturing Technology 9-10/2021

25-02-2021 | ORIGINAL ARTICLE

Prediction of white layer formation in μ-WEDM process of NiTi shape memory superalloy: FEM with experimental verification

Authors: Reza Najati Ilkhchi, Samet Akar, Hassan Ali M. Meshri, Mirsadegh Seyedzavvar

Published in: The International Journal of Advanced Manufacturing Technology | Issue 9-10/2021

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Abstract

Microscopic changes in the surface of nickel-titanium (nitinol) shape memory alloys (SMAs) in micro-wire electro-discharge machining (μ-WEDM) due to the formation of a resolidified layer on the machined surface, called white layer, are one of the main drawbacks in the processing of such alloys. Since these changes significantly affect the shape memory and elastic recovery characteristics of these alloys, reduction of the white layer thickness (WLT) based on the selection of optimum process parameters is essential to raise the quality of the machined parts. In this regard, a finite element model (FEM) has been developed to simulate the effects of μ-WEDM process parameters, including discharge current, pulse on-time, pulse off-time, and servo voltage, on the heat distributing in Ni55.8Ti SMA to predict the WLT. The flushing efficiency of electric discharges and the effect of flow regime of the dielectric fluid on the heat distribution in the workpiece and the formation of the WLT are analyzed. Experimental data are used to verify the accuracy of the FEM. The results show that the developed model can predict the WLT in μ-WEDM process of Ni55.8Ti SMA with an average error of 14%. The effects of discharge parameters on the formation of the WLT are discussed in details based on the results of the FEM.
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Metadata
Title
Prediction of white layer formation in μ-WEDM process of NiTi shape memory superalloy: FEM with experimental verification
Authors
Reza Najati Ilkhchi
Samet Akar
Hassan Ali M. Meshri
Mirsadegh Seyedzavvar
Publication date
25-02-2021
Publisher
Springer London
Published in
The International Journal of Advanced Manufacturing Technology / Issue 9-10/2021
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI
https://doi.org/10.1007/s00170-021-06796-y

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