Wire Electric Discharge Machining at Different Slant Angles during Slant Type Taper Profiling of Microfer 4722 Superalloy

Abstract

Wire electric discharge machining (WEDM) is nonconventional machining that provides machining solutions irrespective of the material hardness. In the present study, a simple profile was machined on Microfer 4722 at different slant angles using to know the effect of machining parameters. A unique method of obtaining taper components was employed by slant type taper fixture to avoid the disadvantages of the conventional method. The profiling speed, profile roughness, profiling error (Corner error), recast layer thickness, micro-hardness, microstructural and metallurgical changes of the machined component were investigated. As the taper of the component increases the profile roughness, corner error increases although profiling speed decreases. It is observed that recast layer thickness decreases as the taper of the component increases. A contrasting phenomenon is observed in the case of hardness at the WEDM surface. The metallurgical changes like the addition of Cu, Zn and O in the nickel-based alloy after machining from WEDM at different slant angles are highlighted. It is observed that residual stress decreased as the slant angles increased from 0° to 30° during slant type profiling. © 2021, ASM International.