Outline of Current Research on Surface

Texturing, Grinding and EDM

1. Grinding effects on surface integrity and mechanical strength

OUTLINE
Fine-grained WC-13 wt % Co grade and three different surface conditions: (1)
ground, (2) mirror-like polished (reference), and (3) ground plus high-temperature
annealed, were investigated.
During grinding a damaged thin layer of fragmented carbides, micro cracking and
high compressive residual stress is formed.
Strength of the hard metal is enhanced by grinding, as compared to the intrinsic
one measured for the polished reference condition. This mainly results from
grinding-induced changes on effective location, from surface into subsurface levels,
of the strength controlling flaw.
On the other hand, such strength increase is completely lost after annealing the
ground specimens as high temperature annealing for relieves mechanically
induced residual stresses.
RESEARCH ISSUES
Grinding effect on fracture is still not understood clearly.
Strength increase is lost after relieving the surface compressive residual stresses
by heat treatment.

REFERENCE
J.YANG, M.ODN, M.P. JOHANSSON-JESAAR, L.LLANES
Grinding effects on surface integrity and mechanical strength of WC-Co cemented
carbides
http://www.sciencedirect.com/science/article/pii/S2212827114000456

2. Influence of the macro-topography of grinding wheels

OUTLINE
The cooling efficiency in grinding can be enhanced by altering the macro-
topography of the grinding wheel. Three different grinding wheels - standard
grinding wheel with continuous layer, a slotted grinding wheel, a segmented
grinding wheel were tested and their respective cooling efficiency was evaluated.
In high-performance grinding, the thermal loads prevail and leads to tempered and
rehardening zones.
 The highest depths of alteration of surface integrity occurred for the segmented
wheel, even resulting in rehardening zones, while the slotted wheel only resulted
into a small depth.
The slotted grinding wheel showed the best cooling efficiency and ultimately the
least impact on the surface integrity.

RESEARCH ISSUE
The slotted grinding wheels potential for creep feed mode can be further
investigated.

REFERENCE
B. KIRSCH, J.C. AURICH
Influence of the macro-topography of grinding wheels on the cooling efficiency and
the surface integrity
http://www.sciencedirect.com/science/article/pii/S2212827114000031

3. Comparison of surface textures generated in hard turning

and grinding
OUTLINE
Two turned and ground surfaces with the same Ra roughness parameter of about
0.3 m were compared to characterize 3D surface roughness parameters.
The textures of hard turned are periodic-anisotropic and ground surfaces mixed
periodicrandom anisotropic.
3D BAC curves reveal that ground hard surfaces have better bearing properties.
This is due to negative skewness Ssk value and lower surface bearing index Sbi
value for ground topographies.
Ground surfaces also have better fluid retention ability. This is due to deeper and
wider grooves as well as higher average density of valleys.

RESEARCH ISSUE
Improvement of surface texture in Precision hard turning should be further
investigated.

REFERENCE
WIT GRZESIKA, KRZYSZTOF AKA, PIOTR KISZKAA
Comparison of surface textures generated in hard turning and grinding operations
http://www.sciencedirect.com/science/article/pii/S221282711400016X

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4. Surface grind hardening induced residual stresses
OUTLINE
Surface residual stresses on ground workpieces is a result of the thermal
deformation due to heat dissipation in the grinding zone, the pressure between the
grinding wheel and the workpiece, and the phase transformation of the material
structure.
A FEA analysis was done to calculate the residual stresses due to the grinding are
pressure (mechanical) and the thermal deformation. The residual stresses due to
phase transformation cannot be determined directly. For this a separate module
was developed that calculated the resulting stress due to phase change.
Grind-hardening without coolant resulted in tensile residual stresses across the
whole depth of the heat treated layer.
Assisting the grind-hardening with coolant produces compressive residual
stresses up to one fourth the hardened layer. The use of coolant fluid increases
the efficiency of martensite transformation.

RESEARCH ISSUE
Finite Element Analysis of grinding effects on other materials need to be done.

REFERENCE
KONSTANTINOS SALONITIS
On surface grind hardening induced residual stresses
http://www.sciencedirect.com/science/article/pii/S2212827114000468

5. Surface integrity of fluid jet polished tungsten carbide

OUTLINE
The surface integrity of binderless tungsten carbide after polishing by FJP was
studied experimentally. Two things were focused on: (1) identifying process
conditions under which grain boundaries may dislocate and (2) identify process
conditions under which abrasive particles may become embedded into the
substrate.
For non-submerged nozzle, surface becomes significantly granular and whitened
for inlet pressures above 4 bar. The whitening is linked to light scattering resulting
from degradation in the surface texture.
For the submerged nozzle, this phenomenon could not be observed. The only
visible effect being a slight darkening of the surface, most likely due to removal of
a very thin oxide layer on the WC surface.

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 Under certain process parameters abrasive particles can become embedded into
the tungsten carbide surface after polishing by FJP due to unreleased elastic
contact.

RESEARCH ISSUE
Dislocation of grain boundaries, unintentional loss of grains from the work piece
can be investigated for other finishing processes such as hard turning, grinding.

REFERENCE
ANTHONY BEAUCAMP, YOSHIHARU NAMBA, WILHELMUS MESSELINK, DAVID
WALKER,
PHILLIP CHARLTON, RICHARD FREEMAN
Surface integrity of fluid jet polished tungsten carbide
http://www.sciencedirect.com/science/article/pii/S2212827114000651

6. The effect of surface texturing on reducing the friction and

wear of steel
OUTLINE
The generation of hydrodynamic pressure, micro-trap for wear debris, and the
micro-reservoirs for lubricant retention are the main mechanisms for reducing the
friction and wear with surface texturing.
To explain the mechanism a numerical model of multidimples based on the
Reynolds equation was developed.
Textured samples can generate greater hydrodynamic pressure compared with
the non-textured sample and will thus increase the load carrying capacity.
The generation of the surface texturings hydrodynamic pressure is crucial to
reducing friction and wear, and 5% is the optimal dimple area fraction value for
achieving minimum friction and wear.

RESEARCH ISSUE
Effects of dimple patterns on mechanical strength, fatigue failure of the workpiece
have not been accounted.

REFERENCE
WEI TANG, YUANKAI ZHOU, HUA ZHU, HAIFENG YANG
The effect of surface texturing on reducing the friction and wear of steel under
lubricated sliding contact
http://www.sciencedirect.com/science/article/pii/S0169433213003061

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7. WEDM of titanium alloy
OUTLINE
Pulse width, peak current and time between two pulses significantly affect the
cutting speed values in WEDM of titanium by high speed brass wire and zinc
coated wire.
The zinc-coated brass wire can produce smoother surface in comparison with high
speed brass. The existence of zinc in coated brass wire provides higher tensile
strength for wire. The wire with high tensile strength is a good heat resistance in
high temperature and maintains straight under vibration and tension. Also, the
uniform zinc layer on coated wire provides good discharge characteristics.
Wire rupture probability enhances when pulse-width increases and time between
two pulses decreases simultaneously.
Wire mechanical tension and injection pressure are effective parameters in
reduction of wire breakage when pulse width and time between two pulses are
small and large enough respectively.
REFERENCE
FARNAZ NOURBAKHSH, K. P. RAJURKAR, A. P. MALSHE, JIAN CAO
Wire electro-discharge machining of titanium alloy
http://www.sciencedirect.com/science/article/pii/S2212827113000048

8. Influence of the WEDM process on the fatigue behavior of

Inconel 718
OUTLINE
The surface roughness obtained with WEDM (applying one rough cut and two trim
cuts) is similar (Ra = 0.58) that obtained with grinding (Ra = 0.53), and it follows a
random pattern, obtaining similar roughness values in any direction. Both
processes show a minimum heat affected layer, which is higher in the ground case.
The white layer generated in WEDM has a variable thickness, and it disappears in
some zones of the surface.
The combination of high residual tensile stress, surface roughness an microcracks
generated in the surface of WEDM-manufactures samples have the effect of
decreasing the fatigue strength, particularly at high cycles.

REFERENCE
IZARO AYESTA, BORJA IZQUIERDO, OLATZ FLAO, JOSE ANTONIO SNCHEZ,
JOSEBA ALBIZURI, RAFAEL AVILS
Influence of the WEDM process on the fatigue behavior of Inconel 718
http://www.sciencedirect.com/science/article/pii/S0142112316302158

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9. Workpiece surface roughness and integrity after WEDM
OUTLINE
Controlling the electrical pulse shape and frequency (with ultra high frequencies in
the order of 10 MHz) can minimize electrolysis, the thermal influence of the
discharge and workpiece surface damage with reduced pulse time (between 50
and 1000 ns).
Discharge energy is dependent on the pulse profile, which typically varies widely
between different machines.
Characteristic matte EDM workpiece surfaces were obtained.
Virtually recast free surfaces were found after four trim cuts; also no thermal
banding was obvious.
Microstructure appeared consistent/unchanged below the recast layer.

RESEARCH ISSUES
Process productivity is a factor where multiple trim passes are utilized however
WEDM systems are suited to unmanned/24 h operation.

REFERENCE
D.K. Aspinwall,S.L. Soo, A.E. Berrisford, G. Walder
Workpiece surface roughness and integrity after WEDM of Ti6Al4V and
Inconel 718 using minimum damage generator technology
http://www.sciencedirect.com/science/article/pii/S000785060800067X

10. Surface modification by Electrical Discharge

OUTLINE
Wire cutting of Ti6Al4V and -TiAl produced surface roughness values around
3.512.3 m and the thickness of recast layer varied from 1 to 136 m. The
recast layers were non-uniform in all cases and workpieces cut with nickel wire
tended to produce thinner recast layers than with copper wire.
Roll texturing/surface alloying with partially sintered WC/Co tool electrodes
produced a significantly harder alloyed layer.
Texturing with graphite or copper tool electrodes followed by Cr plating gave an
30% lower friction force than those textured/alloyed with partially sintered WC/Co
electrodes.

REFERENCE
H.G. Lee, J. Simao, D.K. Aspinwall, R.C. Dewes, W. Voice
Electrical discharge surface alloying
http://www.sciencedirect.com/science/article/pii/S0924013604001761

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11. Electrical discharge machining of titanium alloy
OUTLINE
Effect of EDM parameters - pulse current and pulse duration on various aspects
of the surface integrity were performed for three types of electrodes.
With the increase of pulse current and pulse duration, the deeper craters and
global appendages on the surface become more evident. Surfaces become
rougher.
Average white layer thickness increases as the pulse on duration increases for a
constant pulse current.
Residual stresses are also created at the surface and when the stress in the
surface exceedsvthe materials ultimate tensile strength, cracks are formed.
Surface crack density is related to average white layer thickness and the thicker
the white layer the lower the surface crack density. Surface cracking can be
eliminated after 6 and 3 A pulse currents for aluminium and graphite electrodes.
Graphite electrode gives the highest material removal rate, followed by electrolytic
copper and aluminium. Graphite exhibits the lowest wear rate due to higher melting
point at all the applied condition.
Aluminium electrode shows the best performance with regard to surface finish.
REFERENCE
Ahmet Hascalk, Ulas Caydas
Electrical discharge machining of titanium alloy (Ti6Al4V)
http://www.sciencedirect.com/science/article/pii/S0169433207006988

12. Effect of Grinding and Wire EDM on Fatigue Strength and

Surface Integrity
OUTLINE
Both ground and WEDMed surfaces show heat affected zones after the fatigue
test.
In case of the ground sample, a big thermally influenced rim zone can be seen.
The thickness of this zone can be high as 8 m. Furthermore grain deformation,
sharp cracks and craters have been detected.
In case of WEDMed sample, big thermally influenced zones were detected. The
occurring marks are shaped like shells. They reach up to 20 m into the bulk
material. Between the shells there is a continuous layer with an average thickness
of 5 m.
Process instabilities, which occur during Wire EDM of Ti6Al4V can directly be seen
on the surface as black marks.

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 REFERENCE
F. Klocke, D. Welling, J. Dieckmann
Comparison of grinding and Wire EDM concerning fatigue strength
and surface integrity of machined Ti6Al4V components
http://www.sciencedirect.com/science/article/pii/S1877705811029080

13. Surface integrity of Ti6Al4V alloy machined by EDM and

AECG
OUTLINE
EDMed Surface has a complex appearance covered by craters, spherical particles
and melted drops. The spherical particles are the molten metals that are expelled
randomly during the discharge and then solidified and attached to the surface.
An increase in current intensity leaded to noticeable surface roughness of
specimens.
Abrasive electrochemical grinded (AECG) surface has a strongly attached TiO film
at the lower voltages. It hinders the current flow between the wheel and workpiece.
The contact of abrasives on surface decreased with feed rate and surface
roughness was improved by eliminating abrasive damages.

REFERENCE
Ahmet Hascalk, Ulas Caydas
A comparative study of surface integrity of Ti6Al4V alloy machined by EDM and
AECG
http://www.sciencedirect.com/science/article/pii/S092401360700297X

14. Surface Integrity and Fatigue Study of Wire-EDM

OUTLINE
The relation between the surface integrity and HCF behavior was analyzed on
a bending fatigue test bed.
Grinding process used as a reference shows the highest fatigue strength. The
fatigue strength of the wire-EDMed and broached specimen are in the same
magnitude.
Fractured surface of a wire-EDMed specimen can be divided in a fatigue and
a fracture area. The structure of the fatigue area is finer than the structure of
the fracture area. The areas are separated through a crack growth frontier.

REFERENCE
D. Welling
Results of Surface Integrity and Fatigue Study of Wire-EDM Compared to
Broaching and Grinding for Demanding Jet Engine Components Made of Inconel
718
http://www.sciencedirect.com/science/article/pii/S2212827114000584