Comparative Analysis of Different WEDM Strategies Applied to Cut WC-Co Cemented Carbides

Cemented carbides WC-Co feature high mechanical properties and outstanding wear resistance. Traditional grinding of such hard workpiece features low material removal rate and diminished tool life. Notwithstanding that, even if, proper cooling fluid is applied; abrasive machining of cemented carbides characterizes poor efficiency. The aim of this study was to investigate the issue of WEDM of the cemented carbides WC-Co with two alternative materials of the wire electrodes applied. The presented experimental surface layer geometry measurements was carried out on a modern profilometer MITUTOYO SV 3200. Especially, WEDM results with wire flushing and in immersion were compared. Investigated were the effects of such input parameters as the pulse width and the time between two pulses on the output parameters such as area cutting efficiency, workpiece surface roughness in 2D and 3D. Analysing SEM microphotographs the surface layer defects after WEDM, cobalt depletion and pitting was discoursed. The analysed results provided WEDM of WC-Co cemented carbides with molybdenum wire electrode as seventy one percent less efficient and higher roughness was obtained for the same number of passes. The lowest height of the roughness on the surface after cutting with molybdenum wire amounted to Ra and Sa = 3.5 μm. Such roughness involves a 25 μm deep undesirable heat affected zone. WEDM with equal number of passes and brass wire resulted in roughness Ra and Sa =0,9 μm. In further research, an endeavour should be directed to examine different water and hydrocarbons derivative dielectrics impact on the surface layer structure and chemical composition of the machined WC-Co carbides.