Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts
Wire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys...
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| Veröffentlicht in: | Materials 2022-12, Vol.16 (1), p.100 |
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| creator | Mouralova, Katerina Bednar, Josef Benes, Libor Prokes, Tomas Zahradnicek, Radim Fries, Jiri |
| description | Wire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box-Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5-160 mm thicknesses, both on the surface and in the subsurface layer. |
| doi_str_mv | 10.3390/ma16010100 |
| format | Article |
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The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box-Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5-160 mm thicknesses, both on the surface and in the subsurface layer.</description><identifier>ISSN: 1996-1944</identifier><identifier>EISSN: 1996-1944</identifier><identifier>DOI: 10.3390/ma16010100</identifier><identifier>PMID: 36614437</identifier><language>eng</language><publisher>Switzerland: MDPI AG</publisher><subject>Alloys ; Analysis ; Automobile industry ; Copper alloys ; Copper base alloys ; Cutting parameters ; Cutting speed ; Electric discharge machining ; Electric properties ; Electrical conductivity ; Electrical resistivity ; Experiments ; Heat conductivity ; Influence ; Injection molding ; Machine tools ; Machining ; Mathematical models ; Molds ; Optimization ; Optimization techniques ; Process parameters ; Regression models ; Surface properties ; Taguchi methods ; Technology application ; Thermal conductivity ; Thickness ; Topography ; Transportation equipment industry ; Variance analysis</subject><ispartof>Materials, 2022-12, Vol.16 (1), p.100</ispartof><rights>COPYRIGHT 2022 MDPI AG</rights><rights>2022 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/). 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The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box-Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5-160 mm thicknesses, both on the surface and in the subsurface layer.</description><subject>Alloys</subject><subject>Analysis</subject><subject>Automobile industry</subject><subject>Copper alloys</subject><subject>Copper base alloys</subject><subject>Cutting parameters</subject><subject>Cutting speed</subject><subject>Electric discharge machining</subject><subject>Electric properties</subject><subject>Electrical conductivity</subject><subject>Electrical resistivity</subject><subject>Experiments</subject><subject>Heat conductivity</subject><subject>Influence</subject><subject>Injection molding</subject><subject>Machine tools</subject><subject>Machining</subject><subject>Mathematical models</subject><subject>Molds</subject><subject>Optimization</subject><subject>Optimization techniques</subject><subject>Process parameters</subject><subject>Regression models</subject><subject>Surface properties</subject><subject>Taguchi methods</subject><subject>Technology application</subject><subject>Thermal conductivity</subject><subject>Thickness</subject><subject>Topography</subject><subject>Transportation equipment industry</subject><subject>Variance analysis</subject><issn>1996-1944</issn><issn>1996-1944</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2022</creationdate><recordtype>article</recordtype><sourceid>ABUWG</sourceid><sourceid>AFKRA</sourceid><sourceid>AZQEC</sourceid><sourceid>BENPR</sourceid><sourceid>CCPQU</sourceid><sourceid>DWQXO</sourceid><recordid>eNpdkt9qFDEUxgdRbKm98QEk4I0IW_NnMpncCEtbtdChBVu8DNnMyW7qTDImmUr7Gn1hU7fWas5FQvL7vpMPTlW9JviAMYk_jJo0mJTCz6pdImWzILKunz8571T7KV3hshgjLZUvqx3WNKSumdit7jqdNzDq7IweUBd6GBKyIaJOm43zzq_R2ZTd6G4LEjwKFi3HyYQh3CDG0U-XN-jIWQsRfEYXG2e-e0gJErpM9-Jvx0cdygGdjFMM14BKM_R1jlYbQOcxTBCzK3Cx7cLQo3Mdc3pVvbB6SLD_sO9Vl5-OLw6_LE7PPp8cLk8Xpq55XkjTc9ITY6W2AhMpes5sD5oSDJjzpl1ZzbVu8aqthdSCAsfMGo6tlUQYyfaqj1vfaV6N0JuSIOpBTdGNOt6ooJ3698W7jVqHayVbShrSFoN3DwYx_JghZTW6ZGAYtIcwJ0VFQ2RLKGsK-vY_9CrM0Zd4vykiaUNpoQ621FoPoJy3ofQ1pXoYnQkerCv3S1FzUVNKRBG83wpMDClFsI-_J1jdz4f6Ox8FfvM07yP6ZxrYLxYzttE</recordid><startdate>20221222</startdate><enddate>20221222</enddate><creator>Mouralova, Katerina</creator><creator>Bednar, Josef</creator><creator>Benes, Libor</creator><creator>Prokes, Tomas</creator><creator>Zahradnicek, Radim</creator><creator>Fries, Jiri</creator><general>MDPI AG</general><general>MDPI</general><scope>NPM</scope><scope>AAYXX</scope><scope>CITATION</scope><scope>7SR</scope><scope>8FD</scope><scope>8FE</scope><scope>8FG</scope><scope>ABJCF</scope><scope>ABUWG</scope><scope>AFKRA</scope><scope>AZQEC</scope><scope>BENPR</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>D1I</scope><scope>DWQXO</scope><scope>HCIFZ</scope><scope>JG9</scope><scope>KB.</scope><scope>PDBOC</scope><scope>PIMPY</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>7X8</scope><scope>5PM</scope><orcidid>https://orcid.org/0000-0002-6025-2520</orcidid><orcidid>https://orcid.org/0000-0001-9776-6878</orcidid></search><sort><creationdate>20221222</creationdate><title>Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts</title><author>Mouralova, Katerina ; 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The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box-Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5-160 mm thicknesses, both on the surface and in the subsurface layer.</abstract><cop>Switzerland</cop><pub>MDPI AG</pub><pmid>36614437</pmid><doi>10.3390/ma16010100</doi><orcidid>https://orcid.org/0000-0002-6025-2520</orcidid><orcidid>https://orcid.org/0000-0001-9776-6878</orcidid><oa>free_for_read</oa></addata></record> |
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| source | PubMed Central Open Access; MDPI - Multidisciplinary Digital Publishing Institute; EZB-FREE-00999 freely available EZB journals; PubMed Central; Free Full-Text Journals in Chemistry |
| subjects | Alloys Analysis Automobile industry Copper alloys Copper base alloys Cutting parameters Cutting speed Electric discharge machining Electric properties Electrical conductivity Electrical resistivity Experiments Heat conductivity Influence Injection molding Machine tools Machining Mathematical models Molds Optimization Optimization techniques Process parameters Regression models Surface properties Taguchi methods Technology application Thermal conductivity Thickness Topography Transportation equipment industry Variance analysis |
| title | Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts |
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