Temperature Field Analysis and Machining Modeling of Inconel 718 for Wire Electrical Discharge Machining

doi:10.12068/j.issn.1005-3026.2025.20230278

Abstract

Abstract:

Aiming at the characteristics of Inconel 718 material such as high work hardening rate and large cutting temperature variation， the machining mechanism and modeling of Inconel 718 were deeply studied by taking the discharge machining process of wire electrical discharge machining as the research object. The temperature field of single-pulse discharge is analyzed by the finite difference method and finite element simulation， and the theoretical and simulation temperature distribution results under given parameters are obtained. Furthermore， the law of the influence of pulse width on the size and shape of the corrosion pit is further explored. On the basis of considering the influence of the recast layer on the size of the pit， the surface roughness and material removal rate of machining are predicted and compared with the experimental data. The results show that with the change of pulse width， the variation trend of the theoretical and simulated electric pit dimensions is consistent. The maximum error between theoretical and simulation data and experimental results is 9.88%.

Key words: wire electrical discharge machining, Inconel 718, finite difference method, finite element method, temperature field analysis, recast layer

CLC Number:

TG 66

Yao-man ZHANG, Shuang-jin WU, Zhao-feng RAO. Temperature Field Analysis and Machining Modeling of Inconel 718 for Wire Electrical Discharge Machining[J]. Journal of Northeastern University(Natural Science), 2025, 46(3): 88-96.

Figures/Tables 26

Fig.1 Physical model of single-pulse spark discharge

Fig.2 Diagram of the boundary condition model

Fig.3 Diagram of the inner nodes

Fig.4 Diagram of the nodes on the boundary

Table 1 Physical parameters of Inconel 718

ρ/(kg·m^-3)	c/[J·(kg·℃)^-1]	λ/[W·(m·℃)^-1]	θ_r /℃
8 240	520	20	1 320

Fig.5 Cloud image of overall temperature distribution

Fig.6 Temperature distribution along axes

Fig.7 Dimension of the corrosion pit

Fig.8 Size variation of the corrosion pit with pulse width

Fig.9 Geometric model division and load application

Fig.10 Cloud image of temperature field distribution

Fig.11 Effect of pulse width on the corrosion pit size

Fig.12 Material erosion result at pulse width of 8 μs

Fig.13 Simplified model of corrosion pit

Fig.14 Superimposed surface of the corrosion pits

Fig.15 Two corrosion pits’ superimposed coordinates

Table 2 Theoretical and simulation values comparison of process targets

脉冲宽度/μs	粗糙度/μm		材料去除率/(mm³·min^-1)
脉冲宽度/μs	理论值	仿真值	理论值	仿真值
4	2.114	2.174	4.058	4.380
6	2.584	2.625	6.543	7.139
8	2.850	2.923	9.214	9.889
10	3.114	3.163	10.209	11.201
12	3.292	3.495	11.190	1.260

Fig.16 Schematic diagram of the wire cutting system

Fig.17 Experimental diagram of WEDM

Table 3 Processing conditions of experimet

空载电压/V	峰值电流/A	脉冲间隔/μs	走丝速度/(m·min^-1)	电极丝张力/N	工作液
100	20	35	10	16	去离子水

Fig. 18 Diagram of workpiece after experimental processing

Fig.19 Diagram of slot measurement by selected points

Fig.20 Diagram of surface roughness measurement by selection points

Table 4 Results of the single factor pulse width

序号	脉冲宽度/μs	去除率/(mm³·min^-1)	粗糙度/μm
1	4	4.192	2.325
2	6	7.205	2.482
3	8	9.346	2.763
4	10	10.816	3.045
5	12	1.417	3.351

Fig.21 Influence of pulse width on various processing objectives for Inconel 718

Fig.22 Comparison of data results under various processing objectives

References 20

1	汤雁冰，沈新旺，刘志红，等. 激光选区熔化 Inconel 718 合金在 NaOH 溶液中的腐蚀行为［J］. 金属学报， 2022， 58（3）： 324-333.
	Tang Yan-bing， Shen Xin-wang， Liu Zhi-hong， et al. Corrosion behaviors of selective laser melted inconel 718 alloy in NaOH solution ［J］. Acta Metallurgica Sinica， 2022， 58（3）： 324-333.
2	Xu J H， Gruber H， Boyd R， et al. On the strengthening and embrittlement mechanisms of an additively manufactured nickel-base superalloy ［J］. Materialia， 2020， 10： 100657.
3	Cantero J L， Díaz-Álvarez J， Miguélez M H， et al. Analysis of tool wear patterns in finishing turning of Inconel 718 ［J］. Wear， 2013， 297（1/2）： 885-894.
4	Rakesh M， Datta S， Mahapatra S S. Effects of depth of cut during machining of inconel 718 using uncoated WC tool ［J］. Materials Today： Proceedings， 2019， 18： 3667-3675.
5	Raykar S J， Chaugule Y G， Pasare V I， et al. Analysis of microhardness and degree of work hardening （DWH） while turning Inconel 718 with high pressure coolant environment ［J］. Materials Today： Proceedings， 2022， 59： 1088-1093.
6	邓鹏，董长双. 钛合金Ti-6Al-4V的电火花线切割参数试验研究［J］. 机械设计与制造， 2017（1）：69-71，75.
	Deng Peng， Dong Chang-shuang. Experimental research on parameters of the WEDM cutting Ti-6Al-4V titanium alloy ［J］. Machinery Design & Manufacture， 2017（1）： 69-71， 75.
7	Hsu W H， Chien W T. Effect of electrical discharge machining on stress concentration in titanium alloy holes ［J］. Materials， 2016， 9（12）： 957.
8	Kong L L， Liu Z D， Qiu M B， et al. Machining characteristics of submersed gas-flushing electrical discharge machining of Ti6Al4V alloy ［J］. Journal of Manufacturing Processes， 2019， 41： 188-196.
9	Joshi S N， Pande S S. Intelligent process modeling and optimization of die-sinking electric discharge machining ［J］. Applied Soft Computing， 2011， 11（2）： 2743-2755.
10	Kojima A， Natsu W， Kunieda M. Spectroscopic measurement of arc plasma diameter in EDM ［J］. CIRP Annals， 2008， 57（1）： 203-207.
11	Bhanu V， Rao D P S. Gaussian energy distribution of a RC-circuit based single discharge pulse in micro-EDM［J］. International Journal of Innovative Technology and Exploring Engineering， 2019， 8（10）： 4347-4350.
12	Zhang Y M， Guo S Y， Zhang Z， et al. Simulation and experimental investigations of complex thermal deformation behavior of wire electrical discharge machining of the thin-walled component of Inconel 718［J］. Journal of Materials Processing Technology， 2019， 270： 306-322.
13	刘岗，胡永俊，李风，等. 高锰钢上等离子熔覆 Ni60A 镍基合金的温度场模拟［J］. 电镀与涂饰， 2016， 35（6）： 325-330， 339.
	Liu Gang， Hu Yong-jun， Li Feng， et al. Numerical simulation of temperature field for plasma cladding of Ni60A nickel-based superalloy on high-manganese ［J］. Electroplating & Finishing， 2016， 35（6）： 325-330， 339.
14	毕方淇，李丽，吴亚州. 电火花深小孔加工有限元仿真：稳态流场下单脉冲放电瞬态温度场分析［J］. 机械科学与技术， 2016， 35（6）： 956-960.
	Bi Fang-qi， Li Li， Wu Ya-zhou. FEM simulation of deep small hole edm-transient temperature field analysis of single pulse discharge under steady-state flow ［J］. Mechanical Science and Technology for Aerospace Engineering， 2016， 35（6）： 956-960.
15	Mouralova K， Polzer A， Benes L， et al. Machining of B1914 nickel-based superalloy using wire electrical discharge machining ［J］. Proceedings of the Institution of Mechanical Engineers， Part E： Journal of Process Mechanical Engineering， 2021， 235（6）： 2141-2153.
16	王蕾，郭鲁荻，戴恩成. 基于灰色关联分析法的 GH4169 合金电火花线切割加工参数优化［J］. 航空精密制造技术， 2020， 56（2）： 31-34.
	Wang Lei， Guo Lu-di， Dai En-cheng. Parameter optimization of GH4169 alloy in WEDM based on gray correlation［J］. Aviation Precision Manufacturing Technology， 2020， 56（2）： 31-34.
17	Kumar A， Singh S. Parametric optimization of wire electro discharge machining of Inconel 718 using Taguchi ’s methodology ［J］. Materials Today： Proceedings， 2021， 43： 2025-2031.
18	崔景芝. 微细电火花加工的基本规律及其仿真研究［D］. 哈尔滨：哈尔滨工业大学， 2007.
	Cui Jing-zhi. Basic law of micro-EDM and its simulation research ［D］. Harbin： Harbin Institute of Technology， 2007.
19	楼乐明. 电火花加工计算机仿真研究［D］. 上海：上海交通大学，2000.
	Lou Le-ming. Research on computer simulation of EDM ［D］. Shanghai： Shanghai Jiao Tong University， 2000.
20	Izquierdo B， Sanchez J， Plaza S， et al. On the characterization of the heat input for thermal modelling of the EDM process［C］// Proceedings of the 16th International Symposium on Electromachining： Department of Mechanical Engineering. Bilbao， 2010： 26-31.

[1]	Hong GUAN, Qian XIONG, Hui MA, Wei-wei WANG. Fault Feature Extraction and Analysis of Rotating Blade Cracks [J]. Journal of Northeastern University(Natural Science), 2025, 46(3): 60-68.
[2]	Zhi-qiang WANG, Zhen-yu LEI. Effects of Surface Periodic Roughness on Contact Stick-Slip Behaviors [J]. Journal of Northeastern University(Natural Science), 2025, 46(1): 76-82.
[3]	Chong SHEN, Qing-tian SU, You-sheng CHEN. Mechanical Properties and Reinforcement Method of Misaligned Thick Plate Cross Joints in Steel Bridge [J]. Journal of Northeastern University(Natural Science), 2024, 45(5): 729-737.
[4]	LU Xiao-hong， GU Han， CONG Chen， RUAN Fei-xiang. Micro-milling Force Prediction of Inconel 718 Thin-walled Parts [J]. Journal of Northeastern University(Natural Science), 2023, 44(2): 242-250.
[5]	MA Hui， YU Ming-yue， GAO Ang， ZHAO Chen-guang. Dynamic Modeling Method of Bolted Joint Interfaces Based on Nonlinear Transversely Isotropic Virtual Material [J]. Journal of Northeastern University(Natural Science), 2021, 42(8): 1111-1119.
[6]	LI Ming， LIU Ming-rui， ZHOU Li-ming. Cell-Based Smoothed Finite Element Method for Elastic-Electro-Moisture Multi-physical Coupling Field [J]. Journal of Northeastern University Natural Science, 2020, 41(9): 1363-1368.
[7]	LI Wu-jie， GUO Li-xin. Effect of Different Postures on Burst Fracture of Thoracolumbar Segment [J]. Journal of Northeastern University Natural Science, 2020, 41(4): 534-540.
[8]	DENG Wen-juan， ZHANG Ying-li， DING Jia-nan， BA De-chun. CFD-based Performance Analysis of a Discharge Valve Plate in the Rolling Rotor Compressor [J]. Journal of Northeastern University Natural Science, 2020, 41(12): 1754-1759.
[9]	FANG Shu-jun， WANG Tao， NIE Nian-cong， ZHANG Ling-rui. Analysis of Poor Crack Configuration Influence Based on ABAQUS Standard Extended Finite Element Method [J]. Journal of Northeastern University Natural Science, 2020, 41(11): 1646-1653.
[10]	GAO Feng， SUN Wei， GAO Jun-nan. Vibration Characteristics Study for the Hard Coating Blisk Using Finite Element Method [J]. Journal of Northeastern University Natural Science, 2019, 40(5): 688-693.
[11]	HU Sheng， LYU Jiang-tao， SI Guang-yuan. Analysis and Modeling of Electro-osmosis Based on the Modified Poisson-Boltzmann Equation [J]. Journal of Northeastern University Natural Science, 2019, 40(3): 447-451.
[12]	LIU Chang， ZHAO Chun-yu， HAN Yan-long， WEN Bang-chun. Calculation Method for Load Distribution of Ball Screw Nut Pairs [J]. Journal of Northeastern University Natural Science, 2019, 40(12): 1739-1743.
[13]	GONG Ya-dong， MA Xiao-teng， SUN Yao. Experimental Study on the Wire Electrical Discharge Machining of Rotary Parts Based on the Response Surface Method [J]. Journal of Northeastern University Natural Science, 2018, 39(7): 1005-1010.
[14]	LI Peng-fei， LIU Yu， GONG Ya-dong， LI Liang-liang. Iterative Finite Element Method for Predicting Deformations of Micro Thin Wall [J]. Journal of Northeastern University Natural Science, 2018, 39(4): 527-531.
[15]	ZHOU Li-ming， REN Shu-hui， MENG Guang-wei， LI Rong-jia. ABAQUS User Subroutine Development for Energy Releasing Rate of the Functionally Graded Plate with Cracks [J]. Journal of Northeastern University Natural Science, 2017, 38(9): 1309-1314.