Numerical and experimental study on WEDM of BN-AlN-TiB2 composite ceramics based on a fusion FEM model. (April 2022)

• Record Type: Journal Article
• Authors: Ming, Wuyi; Cao, Chen; Shen, Fan; Zhang, Zhen; Liu, Kun; Du, Jinguang; Jia, Haojie
• Is Part Of: Journal of manufacturing processes. Volume 76(2022)
• Page Start: 138
• Page End: 154
• Publication Date: 2022-04
• Subjects: BAT BN-AlN-TiB2 -- Cp Specific heat capacity of BAT composite ceramics -- Dw The diameter of wire electrode -- EDM Electric discharge machining -- fc The energy distribution ratio to the workpiece -- FEM Finite element method -- H Depth of the crater -- hc Heat transfer coefficient between dielectric fluid and workpiece -- I Discharge current -- Km The coefficient of BAT composite ceramics -- Kt Thermal conductivity -- MRR Material removal rate -- q Heat flux -- r Radius -- Ra Surface roughness -- Rc The radius of the crater -- Rd Discharge gap -- Rp Discharge channel radius -- SDE Specific discharge energy -- T Temperature -- t Time -- T0 Initial temperature -- Toff Pulse-off time -- Ton Pulse-on time -- WEDM Wire-EDM -- ρ Density of BAT composite ceramics -- ω Mass fractions; BN-AlN-TiB2 -- Fusion FEM models -- Numerical simulation -- Machining performances -- SDE -- WEDM; Production management -- Data processing -- Periodicals; Manufacturing processes -- Periodicals; Procestechnologie; Productietechniek; Production -- Gestion -- Informatique -- Périodiques; Fabrication -- Périodiques; Manufacturing processes; Production management -- Data processing; Periodicals; 670.5
• DOI: 10.1016/j.jmapro.2022.02.013
• Languages: English
• ISSNs: 1526-6125

Abstract

Abstract: Due to the poor machining performances in the traditional machining process for BN-AlN-TiB2 composite ceramics, this paper investigated the influence of electrical parameters and material composition on the machining performances of wire electrical discharge machining, namely material removal rate (MRR), surface roughness, kerf width, and energy efficiency. To find out the optimal process parameters, a fusion thermo-physical model based on the finite element method was proposed to predict the machining performances of BN-AlN-TiB2 with different weight proportions. Compared with experimental results, the accuracy of the novel model was verified within a relative error of 24.56, 16.16, and 1.87% in MRR, surface roughness, and kerf width, respectively. In addition, a series of experiments were conducted to investigate the effects of process parameters on machining performances for WEDM of different BN-AlN-TiB2 composite ceramics with 6, 8, and 10 wt% TiB2 . The experimental results demonstrated that machining performances were proportional to the discharge energy. Moreover, MRR and specific discharge energy increased with increase of discharge current and pulse-on time. Considering the machining performances and energy efficiency, an appropriate parameter range with discharge current of 6–8 A, pulse-on time of 10–30 μs, and pulse-on time of 4–6 μs was recommended, and the BN-AlN-TiB2 composite ceramics with 6 wt% TiB2 exhibit better energy efficiency during the WEDM process. Highlights: A fusion finite element method model of three-phase ceramics was proposed for WEDM. Investigating the influences of process parameters on machining performances for different BN-AlN-TiB2. The optimal parameter combinations and mass fraction of TiB2 in BN-AlN-TiB2 are recommended.