Regulation of Thermal Deformation Behavior in Wire EDM Process Based on Underwater Laser-induced Shockwave

doi:10.3901/JME.2024.09.273

Abstract

Abstract: The thermal deformation during wire electric discharge cutting (WEDM) processing of thin-walled metals is almost unavoidable, which restricts the application of WEDM in precision machining of thin-walled parts. In this study, a new process of underwater laser-induced shockwave to regulate the bending deformation of thin-wall metal induced by WEDM are proposed, which can obtain low/no deformation thin-wall parts. The thermal deformation of In718 and TC4 thin walls processed with different wire-cutting parameters is calibrated, and the relationship between the thermal and wire-cutting process parameters is obtained. The influence of thin walls' thermal deformation is most obviously affected by pulse time, while the effect of pulse gap is not significant. Based on the results of laser shock simulation and experiment results, the thermal deformation of thin walls can be effectively recovered by selecting suitable laser parameters for impact processing of thin walls. For In718 and TC4 thin walls of different thicknesses, the thermal deformation can be controlled by underwater laser-induced shockwave. When the laser energy is 80 mJ, the spot distance (x-y) is 0.5-0.5 mm, and the number of impacts is 1, the control effect achieves the best. The lowest warpage of all thin walls after regulation is only 1.4 μm, and the thermal deformation can be reduced by up to 98.35%. By testing the surface integrity of the processed thin walls, the results show that this new process can improve the surface hardness of the thin wall by more than 20%, reduce the surface roughness and the thickness of the recast layer, and improve the surface cracks to some extent.

Key words: laser-induced shockwave, wire electrical discharge machining, deformation recovery, metal thin wall

CLC Number:

V261

QIU Wenzhe, ZHANG Zhen, WANG Peng, LIU Denghua, WEI Shichuan, ZHANG Guojun. Regulation of Thermal Deformation Behavior in Wire EDM Process Based on Underwater Laser-induced Shockwave[J]. Journal of Mechanical Engineering, 2024, 60(9): 273-285.

References

[1] Tang H，Tang Y，Wu X，et al. Fabrication and capillary characterization of multi-scale microgroove wicks for ultrathin phase-change heat transfer devices[J]. Applied Thermal Engineering，2023，219：119621.
[2] AHMED H E，SALMAN B H，KHERBEET A S，et al. Optimization of thermal design of heat sinks: A review[J]. International Journal of Heat and Mass Transfer，2018. 118：129-153.
[3] Jin G，Zhan Q，Li W，et al. Study on the control method of flatness of thin-walled parts milled from 7075 aluminum alloy based on ice-fixation[J]. International Journal of Lightweight Materials and Manufacture，2023，6(10)：563-573.
[4] 刘冬敏，上官同英，陈志. 电火花线切割加工薄壁零件热弯曲的形成机制及实验研究[J]. 机床与液压，2019，47(17)：111-114. LIU Dongmin，SHANGGUAN Tongying，CHEN Zhi. Formation mechanism and experiment investigation of thin-walled part thermal deformation using wire electrical discharge machining[J]. Machine Tool & Hydraulics，2019，47(17)：111-114.
[5] Ho K H，Newman S T，Rahimifard S，et al. State of the art in wire electrical discharge machining (WEDM)[J]. International Journal of Machine Tools and Manufacture，2004，44(12)：1247-59.
[6] KUNIEDA T K. Study on factors determining limits of minimum machinable size in micro EDM[J]. CIRP Annals，2005，54(1)：167-170.
[7] ZAHIRUDDIN M，KUNIEDA M. Analysis of micro fin deformation due to micro EDM[J]. Procedia CIRP，2016，42：569-574.
[8] SINGH M，SINGH A，RAMKUMAR J. Thin-wall micromachining of Ti-6Al-4V using micro-wire electrical discharge machining process[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering，2019，41：338.
[9] ZHANG Y，ZHANG Z，HUANG H，et al. Study on thermal deformation behavior and microstructural characteristics of wire electrical discharge machining thin-walled components[J]. Journal of Manufacturing Processes，2018，31：9-19.
[10] 黄浩. 薄壁类零件电火花线切割加工的热变形行为机理与抑制方法[D]. 武汉：华中科技大学，2019. HUANG Hao. Study on thermal deflection mechanism and suppression methodology of thin-walled sections utilizing wire electrical discharge machining[D]. Wuhan：Huazhong University of Science and Technology，2019.
[11] ZHANG Y，ZHANG G，ZHANG Z，et al. Effect of assisted transverse magnetic field on distortion behavior of thin-walled components in WEDM process[J]. Chinese Journal of Aeronautics，2022，35(02)：291-307.
[12] ZHANG Z，QIU W，ZHANG G，et al. Progress in applications of shockwave induced by short pulsed laser on surface processing[J]. Optics& Laser Technology，2023，157：108760.
[13] SALA S T，KELLER S，CHUPAKHIN S，et al. Effect of laser peen forming process parameters on bending and surface quality of Ti-6Al-4V sheets[J]. Journal of Materials Processing Technology，2022，305：117578.
[14] ZHANG Z，ZHANG Y，LOUGHLIN M O，et al. Experimental research on global deformation and through-thickness residual stress in laser peen formed aluminum plates[J]. Surfaces and Interfaces，2021，25：101241.
[15] HU Y，HAN Y，YAO Z，et al. Three-dimensional numerical simulation and experimental study of sheet metal bending by laser peen forming[J]. Journal of Manufacturing Science and Engineering，2010，132(6).
[16] HU Y，XU X，YAO Z，et al. Laser peen forming induced two way bending of thin sheet metals and its mechanisms[J]. Journal of Applied Physics，2010，108(7)：073117.
[17] JIANG J，HU Y，HE X. Process-based surface flattening method for laser peen forming of complex geometry[J]. Journal of Manufacturing Processes，2023，92：371-383.
[18] FABBRO R，PEYRE P，BERTHE L，et al. Physics and applications of laser-shock processing[J]. Journal of Laser Applications，1998，10(6)：265-279.
[19] ZHANG W，YAO Y LAWRENCE，NOYAN I C. Microscale laser shock peening of thin films，part 1：Experiment，modeling and simulation[J]. Journal of Manufacturing Science and Engineering，2004，126(1)：10-17.
[20] JOHNSON G R，COOK W H. A constitutive model and data for metals subjected to large strains，high strain rates and high temperatures[J]. Engineering Fracture Mechanics，1983，21：541-548.
[21] 聂祥樊，李应红，何卫锋，等. 航空发动机部件激光冲击强化研究进展与展望[J]. 机械工程学报，2021，57(16)：13. NIE Xiangfan，LI Yinghong，HE Weifeng，et al. Research progress and prospect of laser shock peening technology in aero-engine components[J]. Journal of Mechanical Engineering，2021，57(16)：13.
[22] SALA S T，KÖRNER R，HUBER N，et al. On the use of machine learning and genetic algorithm to predict the region processed by laser peen forming[J]. Manufacturing Letters，2023，38：60-64.
[23] ZHANG Z，WEI S，WANG P，et al. Progress in applications of laser induced cavitation on surface processing[J]. Optics & Laser Technology，2024，170：110212.
[24] DING K，YE L. Three-dimensional dynamic finite element analysis of multiple laser shock peening processes[J]. Surface Engineering，2003，19(5)：351-358.
[25] 胡永祥. 激光冲击处理工艺过程数值建模与冲击效应研究[D]. 上海：上海交通大学，2008. HU Yongxiang. Research on the numerical simulation and impact effects of laser shock processing[D]. Shanghai：Shanghai Jiao Tong University，2008.
[26] DENG W，WANG C，LU H，et al. Progressive developments，challenges and future trends in laser shock peening of metallic materials and alloys: A comprehensive review[J]. International Journal of Machine Tools and Manufacture，2023，191：104061.