omnaОмский научный вестникOmsk Scientific Bulletin1813-82252541-7541Омский государственный технический университет10.25206/1813-8225-2026-198-40-48RWWOHAomna-406Research ArticleМАШИНОСТРОЕНИЕMECHANICAL ENGINEERINGИсследование гранулометрического состава и морфологии частиц шлама в контексте образования мостиков сварки при электроэрозионной обработке штамповой сталиInvestigation of granulometric composition and morphology of debris particles in the context of welding bridge formation at electrical discharge machining of the stamped steelhttps://orcid.org/0000-0002-0267-8179БредгауэрЮ. О.BredgauerIu. O.

Бредгауэр Юлия Олеговна, старший преподава­тель кафедры «Технология машиностроения»      

644050, г. Омск, пр. Мира, 11

AuthorID (SCOPUS): 57208868308

ResearcherID: ABF-3261-2020

Bredgauer Iuliia Olegovna, Senior Lecturer of the Mechanical Engineering Technology Department    

Mira Ave., 11, Omsk, 644050

AuthorID (SCOPUS): 57208868308

ResearcherID: ABF-3261-2020

jobredgauer@omgtu.ruhttps://orcid.org/0000-0002-6681-087XФедоровА. А.FedorovA. A.

Федоров Алексей Аркадьевич, кандидат техниче­ских наук, доцент, доцент кафедры «Технология ма­шиностроения»    

644050, г. Омск, пр. Мира, 11

AuthorID (SCOPUS): 57193509299

ResearcherID: A-7188-2014

Fedorov Aleksey Arkad’yevich, Candidate of Technical Sciences, Associate Professor, Associate Professor of the Mechanical Engineering Technology Department    

Mira Ave., 11, Omsk, 644050

AuthorID (SCOPUS): 57193509299

ResearcherID: A-7188-2014

aafedorov@omgtu.ruhttps://orcid.org/0000-0001-6799-3105ПолонянкинД. А.PolonyankinD. A.

Полонянкин Денис Андреевич, кандидат педаго­гических наук, доцент кафедры «Физика»    

644050, г. Омск, пр. Мира, 11

AuthorID (SCOPUS): 57201867901

ResearcherID: B-3236-2014

Polonyankin denis Andreevich, Candidate of Pedagogical Sciences, Associate Professor of the Physics Department

Mira Ave., 11, Omsk, 644050

AuthorID (SCOPUS): 57201867901

ResearcherID: B-3236-2014

dapolonyankin@omgtu.ruОмский государственный технический университетРоссияOmsk State Technical UniversityRussian Federation202607072026024048Copyright © Бредгауэр Ю.О., Федоров А.А., Полонянкин Д.А., 20262026Бредгауэр Ю.О., Федоров А.А., Полонянкин Д.А.Bredgauer I.O., Fedorov A.A., Polonyankin D.A.Данная работа распространяется под лицензией Creative Commons Attribution 4.0.This work is licensed under a Creative Commons Attribution 4.0 License.https://onv.omgtu.ru/jour/article/view/406

В статье представлены результаты исследования частиц шлама, включая их элементный состав, а также анализ потенциального влияния шлама на образование мостика сварки, что может приводить к короткому замыканию и обрыву проволоки при проволочно-вырезной электроэрозионной обработке штамповой стали 5ХНМ на станке Sodick VZ 300L.

Для определения размеров, морфологии, формы и элементного состава частиц шлама использованы методы растровой электронной микроскопии, энергодисперсионной рентгеновской спектроскопии и лазерного дифракционного анализа. Установлено, что средние значения размеров частиц шлама составили 25,04 ± 5,26 мкм для образцов, собранных со стола, и 20,97 ± 15,10 мкм — для частиц со дна ванны. Доля эффективных частиц, имеющих критический размер (более 25 мкм) и способствующих образованию мостика сварки, достигает 35 % (для частиц со стола) и 45 % (для частиц со дна ванны). Элементный анализ выявил, что частица состоит из цинка и меди, что соответствует элементному составу материала электрода-инструмента — латуни.

Полученные результаты позволяют лучше понять механизм возникновения дефектов и предложить меры для оптимизации технологического процесса.

This article presents the results of a study of debris particles, including their elemental composition, and an analysis of the potential impact of debris particles on welding bridge formation, which can lead to short circuits and wire breakage during of welding bridge formation at electrical discharge machining of the 5NiCrMo stamp steel on a Sodick VZ 300L machine.

The authors use the scanning electron microscopy, energy-dispersive X-ray spectroscopy and the laser diffraction analysis to determine the size, morphology, shape and elemental composition of debris particles. Moreover, the authors have established that the average debris particles sizes are 25.04 ± 5.26 microns for samples from the tabletop and 20.97 ± 15.10 microns for samples from the bottom of the tub. The proportion of effective particles with a critical size (greater than 25 microns) that contribute to welding bridge formation reaches 35 % (for particles from the tabletop) and 45 % (for particles from the bottom of the tub). An elemental analysis reveals that the particle consists of zinc and copper, corresponding to the elemental composition of the electrode-tool — brass material.

Therefore, the results provide a better understanding of the defect formation mechanism and suggest measures to optimise the process.

проволочно-вырезная электроэрозионная обработкачастицы шламамостик сваркикороткое замыканиерастровая электронная микроскопиялазерный дифракционный анализэлементный составwire electrical discharge machiningdebris particleswelding bridgeshort circuitscanning electron microscopylaser diffraction analysiselemental compositionReferencesObara H. Detection of Discharging Position in Wire EDM. ISEM 10th, 1992. 1992;404. https://cir.nii.ac.jp/crid/1573105974921743872.Obara H. Detection of Discharging Position in Wire EDM. ISEM 10th, 1992. 1992;404. https://cir.nii.ac.jp/crid/1573105974921743872.Obara H. An attempt to detect wire temperature distribution during wire EDM. Proc. of ISEM-11. 1995;67. https://doi.org/10.2526/jseme.28.21.Obara H. An attempt to detect wire temperature distribution during wire EDM. Proc. of ISEM-11. 1995;67. https://doi.org/10.2526/jseme.28.21.Kunieda M., Lauwers B., Rajurkar K. P., Schumacher B. M. Advancing EDM through Fundamental Insight into the Process. CIRP Annals. 2005;54(2):64–87. https://doi.org/10.1016/S0007-8506(07)60020-1.Kunieda M., Lauwers B., Rajurkar K. P., Schumacher B. M. Advancing EDM through Fundamental Insight into the Process. CIRP Annals. 2005;54(2):64–87. https://doi.org/10.1016/S0007-8506(07)60020-1.Dekeyser W., Snoeys R., Jennes M. A thermal model to investigate the wire rupture phenomenon for improving performance in EDM wire cutting. Journal of Manufacturing Systems. 1985;4(2):179–190. https://doi.org/10.1016/0278-6125(85)90024-X.Dekeyser W., Snoeys R., Jennes M. A thermal model to investigate the wire rupture phenomenon for improving performance in EDM wire cutting. Journal of Manufacturing Systems. 1985;4(2):179–190. https://doi.org/10.1016/0278-6125(85)90024-X.Abhilash P. M., Chakradhar D. Failure detection and control for wire EDM process using multiple sensors. CIRP Journal of Manufacturing Science and Technology. 2021;33:315–326. https://doi.org/10.1016/j.cirpj.2021.04.009.Abhilash P. M., Chakradhar D. Failure detection and control for wire EDM process using multiple sensors. CIRP Journal of Manufacturing Science and Technology. 2021;33:315–326. https://doi.org/10.1016/j.cirpj.2021.04.009.Kumar R., Singh I. Productivity improvement of micro EDM process by improvised tool. Precision Engineering. 2018;51:529–535. https://doi.org/10.1016/j.precisioneng.2017.10.008.Kumar R., Singh I. Productivity improvement of micro EDM process by improvised tool. Precision Engineering. 2018;51:529–535. https://doi.org/10.1016/j.precisioneng.2017.10.008.Kunieda M., Yanatori K. Study on Debris Movement in EDM Gap. International Journal of Electrical Machining. 1997;2:43–49.Kunieda M., Yanatori K. Study on Debris Movement in EDM Gap. International Journal of Electrical Machining. 1997;2:43–49.Dong L., Zhigang L., Yiqing W. [et al.]. Study on the movement rule of discharge products in large area titanium alloy machining by electrical discharge machining. Journal of Mechanical Engineering. 2017;53(21):200–208. https://doi.org/10.3901/JME.2017.21.200.Dong L., Zhigang L., Yiqing W. [et al.]. Study on the movement rule of discharge products in large area titanium alloy machining by electrical discharge machining. Journal of Mechanical Engineering. 2017;53(21):200–208. https://doi.org/10.3901/JME.2017.21.200.Li Z., Bai J. Influence of alternating side gap on micro-hole machining performances in micro-EDM. The International Journal of Advanced Manufacturing Technology. 2018;94(1):979–989. https://doi.org/10.1007/s00170-017-0959-9.Li Z., Bai J. Influence of alternating side gap on micro-hole machining performances in micro-EDM. The International Journal of Advanced Manufacturing Technology. 2018;94(1):979–989. https://doi.org/10.1007/s00170-017-0959-9.Tanjilul M., Afzaal Ahmed, Senthil Kumar A. [et al.]. A study on EDM debris particle size and flushing mechanism for efficient debris removal in EDM-drilling of Inconel 718. Journal of Materials Processing Technology. 2018;255:263–274. https://doi.org/10.1016/j.jmatprotec.2017.12.016.Tanjilul M., Afzaal Ahmed, Senthil Kumar A. [et al.]. A study on EDM debris particle size and flushing mechanism for efficient debris removal in EDM-drilling of Inconel 718. Journal of Materials Processing Technology. 2018;255:263–274. https://doi.org/10.1016/j.jmatprotec.2017.12.016.Wang J., Sánchez J. A., Wanget Z. [et al.]. Observations on debris composition and size distribution in WEDM. Procedia CIRP. 2020;95:331–336. https://doi.org/10.1016/j.procir.2020.02.323.Wang J., Sánchez J. A., Wanget Z. [et al.]. Observations on debris composition and size distribution in WEDM. Procedia CIRP. 2020;95:331–336. https://doi.org/10.1016/j.procir.2020.02.323.Iwai H., Ebisu T., Okada A. [et al.]. Influence of nozzle jet flushing on working fluid flow and wire electrode in trimcut WEDM. Procedia CIRP. 2020;95:250–254. https://doi.org/10.1016/j.procir.2020.02.267.Iwai H., Ebisu T., Okada A. [et al.]. Influence of nozzle jet flushing on working fluid flow and wire electrode in trimcut WEDM. Procedia CIRP. 2020;95:250–254. https://doi.org/10.1016/j.procir.2020.02.267.Fujimoto T., Okada A., Okamoto Y. [et al.]. Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. Key Engineering Materials. 2012;516:73–78. https://doi.org/10.4028/www.scientific.net/KEM.516.73.Fujimoto T., Okada A., Okamoto Y. [et al.]. Optimization of nozzle flushing method for smooth debris exclusion in wire EDM. Key Engineering Materials. 2012;516:73–78. https://doi.org/10.4028/www.scientific.net/KEM.516.73.Okada A., Uno Y., Onoda S., Habib S. Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMed kerf. CIRP Annals. 2009;58(1):209–212. https://doi.org/10.1016/j.cirp.2009.03.003.Okada A., Uno Y., Onoda S., Habib S. Computational fluid dynamics analysis of working fluid flow and debris movement in wire EDMed kerf. CIRP Annals. 2009;58(1):209–212. https://doi.org/10.1016/j.cirp.2009.03.003.Yoshida M., Kunieda M. Study on the distribution of scattered debris generated by a single pulse discharge in EDM process. International Journal of Electrical Machining. 1998;3:39–47.Yoshida M., Kunieda M. Study on the distribution of scattered debris generated by a single pulse discharge in EDM process. International Journal of Electrical Machining. 1998;3:39–47.Fedorov A. A., Linovsky A. V., Morgunov A. P. The influence of steel 35 wire EDM parameters on the surface roughness and morphology. Journal of Mechanical Engineering. 2017;14(2):37–49. EDN: UYCJHE.Fedorov A. A., Linovsky A. V., Morgunov A. P. The influence of steel 35 wire EDM parameters on the surface roughness and morphology. Journal of Mechanical Engineering. 2017;14(2):37–49. EDN: UYCJHE.Zhang G., Li H., Zhang Zh. [et al.]. Vibration modeling and analysis of wire during the WEDM process. Machining Science and Technology. 2016;20(2):173–186. https://doi.org/10.1080/10910344.2015.1085312.Zhang G., Li H., Zhang Zh. [et al.]. Vibration modeling and analysis of wire during the WEDM process. Machining Science and Technology. 2016;20(2):173–186. https://doi.org/10.1080/10910344.2015.1085312.

The authors declare that there are no conflicts of interest present.