Experimental investigation on the surface quality of WEDM machined 20MnCr5 steel for gear application

Abstract This experimental study investigates the Wire-cut Electrical Discharge Machining (WEDM) of 20MnCr5 steel, a low alloy steel grade material which is intended for the production of gears, shafts and other parts which need high surface hardness and wear resistance. WEDM is a crucial manufactur...

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Bibliographic Details
Published inMaterials research express Vol. 11; no. 3; pp. 36523 - 36533
Main Authors Vijayakumar, N, Chandradass, J
Format Journal Article
LanguageEnglish
Published Bristol IOP Publishing 01.03.2024
Subjects
20MnCr5 steel
Chromium manganese steels
Electric arcs
Electric discharge machining
Electric potential
Error reduction
Feed rate
Gears
Globules
Low alloy steels
Material removal rate (machining)
Mechanical components
Orthogonal arrays
Parameters
profile error
recast layer
servo voltage
Surface hardness
Surface properties
Surface roughness
Voltage
Wear resistance
WEDM
Wire
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Summary:Abstract This experimental study investigates the Wire-cut Electrical Discharge Machining (WEDM) of 20MnCr5 steel, a low alloy steel grade material which is intended for the production of gears, shafts and other parts which need high surface hardness and wear resistance. WEDM is a crucial manufacturing process for producing gears, shafts, spindles, and various mechanical components. The investigation focuses on three key performance parameters: profile error, material removal rate (MRR), and surface roughness (SR), employing five WEDM parameters—wire feed (W f ), wire tension (W t ), servo voltage (SV), discharge arc-off time (T off ), and arc-on time (T on ) - by employing the Taguchi L 27 orthogonal array. The study reveals that, in comparison to arc-on time and servo voltage, wire feed rate and tension have a lesser impact. Higher arc-on time and servo voltage result in increased profile error, while reduced wire tension values elevate surface roughness. Recast layer formation has been explored under different WEDM input parameters, revealing its dependence on arc-on time, voltage, wire tension, and feed rate. Higher voltage leads to uneven surfaces with larger globules and deep craters, contributing to a thicker recast layer at higher arc-on time and servo voltage.
Bibliography:MRX-128694.R1
ISSN:2053-1591
2053-1591
DOI:10.1088/2053-1591/ad31de