Abstract:

Monel 400 is characterized by high strength over a wide temperature range, excellent resistance to corrosive environments and many acids. Alloy 400 is widely used in many fields, especially marine and chemical processing. Limited thermal conductivity and high cutting forces resulting from long lasting contact of the chip with the tool surface are the problems during cutting. The formation of high temperature on the cutting edge limits the tool life. In addition, copper-based nickel alloys tend to form built-up edge on the cutting tool. A commonly applied solution to increase the machinability of nickel alloys and reduce surface roughness is heat assisted cutting in temperature of max. 600°C. Therefore, in the pursuit of optimizing  machining costs and efficiency while maintaining the desired surface roughness of nickel alloy parts, WEDM is often applied for their shaping. In this paper the results of turning Monel 400 by a cutting tool with modified Wiper type geometry were collated with WEDM (Wire Electrical Discharge Machining). The tool is CuZn37 brass electrode with a diameter of 0.25 mm. The aim of the article was to prove whether WEDM is a viable alternative to traditional machining of copper-based nickel alloys. The analysis of 3D geometry of the Monel surface after turning and WEDM was presented. The most essential possibilities and limitations, of turning with Wiper type tools and WEDM of the Monel alloy, were indicated.