Influence of Wire Electrical Discharge Machining (WEDM) process parameters on surface roughness

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

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Optimasi Multirespon Proses Wire Electrical Discharge Machining untuk Pengerjaan Komponen Punch and Dies Bracket Konstruksi Kapal Alumunium

Jurnal Energi Dan Manufaktur ◽

10.24843/jem.2019.v12.i02.p11 ◽

2019 ◽

Vol 12 (2) ◽

pp. 107

Author(s):

Fipka Bisono ◽

Dhika Aditya P.

Keyword(s):

Surface Roughness ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

White Layer ◽

Performance Characteristics ◽

Machining Process ◽

Wire Electrical Discharge Machining ◽

Process Variables ◽

Relational Analysis ◽

Wedm Process

Wire electrical discharge machining(WEDM) banyak digunakan untuk proses pembuatan punch and dies. Dimana material yang digunakan memiliki tingkat kekerasan yang sangat tinggi. Parameter pemesinan yang kurang tepat dapat menyebabkan hasil pemotongan yang tidak optimal. Penelitian ini dilakukan untuk mengoptimalkan beberapa karakteristik hasil proses pemesinan secara serentak dengan cara mevariasikan variabel-variabel proses pemesinan WEDM. Karakteristik hasil proses yang diteliti antara lain adalah lebar pemotongan, kekasaran permukaan, dan tebal lapisan white layer. Proses pemesinan dilakukan pada material tool steel SKD 11. Arc on time, on time, open voltage dan servo voltage merupakan variabel-variabel proses yang akan divariasikan. Rancangan percobaan dilakukan menggunakan metode Taguchi dengan matriks ortogonal L18(21x33) dengan dua kali replikasi. Sedangkan langkah yang digunakan untuk mengoptimasi karakteristik hasil proses pemesinan yang diteliti secara serentak adalah menggunakan metode grey relational analysis (GRA). Lebar pemotongan, kekasaran permukaan dan tebal lapisan white layer memiliki performance characteristics “smaller-is-better.” Hasil dari penelitian menunjukkan nilai variabel-variabel proses pemesinan yang menghasilkan kualitas karakteristik yang paling optimum adalah sebagai berikut: arc on time (1A), on time (4?s), open voltage (70V), dan servo voltage (40V). Dengan persentase kontribusi variabel proses dari yang terbesar berturut-turut adalah on time (65,09%), open voltage (11,35%), arc on time (7,71%), dan servo voltage (5,61%). Wire electrical discharge machining (WEDM) process is commonly used to make punch and dies. WEDM services are typically used to cut hard metals. Inappropriate machining parameters can cause suboptimal cutting results. This research was conducted to optimize several characteristics of the machining process simultaneously by varying WEDM machining process variables. Performance characteristics of the WEDM process include the kerf, surface roughness and thickness of the white layer. The machining process is carried out on SKD 11 tool steel material. Arc on time, on time, open voltage and servo voltage are process variables that will be varied. The experimental matrix design was carried out using the Taguchi method L18 (21x33) orthogonal array with two replications. Then to optimize the performance characteristics of the machining process simultaneously is using the Gray Relational Analysis (GRA) method. Performance characteristics of kerf, surface roughness, and thickness of the white layer is "smaller-is-better". The results of the experiment indicate the value of the machining process variables that produce the most optimum quality performance characteristics are as follows: arc on time (1A), on time (4?s), open voltage (70V), and servo voltage (40V). And the percentage of contribution of the process variables from the largest to smallest are as follows: on time (65,09%), open voltage (11,35%), arc on time (7,71%), and servo voltage (5,61%).

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Modeling and Optimization of Fractal Dimension in Wire Electrical Discharge Machining of EN 31 Steel Using the ANN-GA Approach

Materials ◽

10.3390/ma12030454 ◽

2019 ◽

Vol 12 (3) ◽

pp. 454 ◽

Cited By ~ 6

Author(s):

Arkadeb Mukhopadhyay ◽

Tapan Barman ◽

Prasanta Sahoo ◽

J. Davim

Keyword(s):

Neural Network ◽

Genetic Algorithm ◽

Fractal Dimension ◽

Process Parameters ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Wire Electrical Discharge Machining ◽

Machining Parameters ◽

Machined Surface ◽

Wedm Process

To achieve enhanced surface characteristics in wire electrical discharge machining (WEDM), the present work reports the use of an artificial neural network (ANN) combined with a genetic algorithm (GA) for the correlation and optimization of WEDM process parameters. The parameters considered are the discharge current, voltage, pulse-on time, and pulse-off time, while the response is fractal dimension. The usefulness of fractal dimension to characterize a machined surface lies in the fact that it is independent of the resolution of the instrument or length scales. Experiments were carried out based on a rotatable central composite design. A feed-forward ANN architecture trained using the Levenberg-Marquardt (L-M) back-propagation algorithm has been used to model the complex relationship between WEDM process parameters and fractal dimension. After several trials, 4-3-3-1 neural network architecture has been found to predict the fractal dimension with reasonable accuracy, having an overall R-value of 0.97. Furthermore, the genetic algorithm (GA) has been used to predict the optimal combination of machining parameters to achieve a higher fractal dimension. The predicted optimal condition is seen to be in close agreement with experimental results. Scanning electron micrography of the machined surface reveals that the combined ANN-GA method can significantly improve the surface texture produced from WEDM by reducing the formation of re-solidified globules.

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Analysis and Optimization of the Machining Characteristics of High-Volume Content SiCp/Al Composite in Wire Electrical Discharge Machining

Crystals ◽

10.3390/cryst11111342 ◽

2021 ◽

Vol 11 (11) ◽

pp. 1342

Author(s):

Hongzhi Yan ◽

Bakadiasa Djo Kabongo ◽

Hongbing Zhou ◽

Cheng Wu ◽

Zhi Chen

Keyword(s):

Surface Roughness ◽

Process Parameters ◽

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

High Volume ◽

Wire Electrical Discharge Machining ◽

Al Composite

With the properties of high specific strength, small thermal expansion and good abrasive resistance, the particle-reinforced aluminum matrix composite is widely used in the fields of aerospace, automobile and electronic communications, etc. However, the cutting performance of the particle-reinforced aluminum matrix composite is very poor due to severe tool wear and low machining efficiency. Wire electrical discharge machining has been proven to be a good machining method for conductive material with any hardness. Even so, the high-volume SiCp/Al content composite is still a difficult-to-machine material in wire electrical discharge machining due to the influence of insulative the SiC particle. The goal of this paper is to analyze the machining characteristics and find the optimal process parameters for the high-volume content (65 vol.%) SiCp/Al composite in wire electrical discharge machining. Experimental results show that the material removal method of the SiCp/Al composite includes sublimating, decomposing and particle shedding. The material removal rate is found to increase with the increasing pulse-on time, first increasing and then decreasing with the increasing pulse-off time, servo voltage, wire feed and wire tension. Pulse-on time and servo voltage are the dominant factors for surface roughness. In addition, the multi-objective optimization method of the nondominated neighbor immune algorithm is presented to optimize the process parameters for a fast material removal rate and low surface roughness. The optimized process parameters can increase the material removal rate by 34% and reduce the surface roughness by 6%. Furthermore, the effectiveness of the Pareto optimal solution is proven by the verified experiment.

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Optimization of Wire Electrical Discharge Machining Parameters of Activated Carbon Reinforced Aluminium Composite

Materials Science Forum ◽

10.4028/www.scientific.net/msf.979.3 ◽

2020 ◽

Vol 979 ◽

pp. 3-9

Author(s):

G. Ramanan ◽

M.Madhu Kiran Reddy ◽

V. Manishankar

Keyword(s):

Activated Carbon ◽

Process Parameters ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Influential Factors ◽

Wire Electrical Discharge Machining ◽

Machining Parameters ◽

Pulse On Time ◽

Pulse Off Time ◽

Wedm Process

The quality of machining through process parameters on the responses in wire electrical discharge machining (WEDM) is studied. This paper discusses the optimization of parameters of a process in WEDM machining with the application of the desirability approach on the basis of response surface methodology (RSM). Pulse on time, servo speed rate, discharge current, and pulse off time have been considered as influential factors. The established experimental data of AA7075 aluminium reinforced with 9% of activated carbon composite to analyze the process parameter effects on responses, like material removal rate (MRR) and surface roughness (SR). After machining multiple regression analysis is used to find the interaction among the process parameters is obtained. The optimal parameters were found using the desirability optimization methodologies as 10.43mm3/min and 3.32μm respectively. The performance of the optimization test confirmed that the proposed method in this study effectively improves the performance of the WEDM process.

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Study on effect of process parameters on MRR and surface roughness in wire electrical discharge machining of titanium grade 7 alloy

Materials Today Proceedings ◽

10.1016/j.matpr.2021.04.555 ◽

2021 ◽

Author(s):

H.R. Basavaraju ◽

R. Suresh ◽

S.S. Manjunath ◽

L. Janardhan

Keyword(s):

Surface Roughness ◽

Process Parameters ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Wire Electrical Discharge Machining ◽

Titanium Grade

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Experimental investigation of Wire Electrical Discharge Machining (WEDM) Process Parameters on SS304 using Taguchi method

International Journal of Current Engineering and Technology ◽

10.14741/ijcet/v.8.3.2 ◽

2018 ◽

Author(s):

T Vijaya Babu ◽

B Subbaratnam

Keyword(s):

Process Parameters ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Wire Electrical Discharge Machining ◽

Taguchi’S Method ◽

Input Parameters ◽

Pulse On Time ◽

Pulse Off Time ◽

Wedm Process

WEDM (Wire Electrical discharge machining) is a nonconventional machining processes used in complicated shapes with high accuracy which are not possible with other conventional methods .Stainless steel 304 is used in present experimental work. Experiments are completed using Taguchi’s method with L9 orthogonal array .The aim of this work is to optimize the WEDM process parameters by considering input parameters are pulse on time , pulse off time ,peak current and wire feed and experiments are conducted with help of input parameters at three levels and response output parameters are MRR (Material removal Rate) and Surface Roughness (SR).Setting of parameters using by Taguchi’s method.

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Experimental Investigation of Machining Parameters on Surface Roughness in Dry and Wet Wire-Electrical Discharge Machining

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.831 ◽

2011 ◽

Vol 264-265 ◽

pp. 831-836 ◽

Cited By ~ 4

Author(s):

Suleiman Abdulkareem ◽

Ahsan Ali Khan ◽

Zakaria Mohd Zain

Keyword(s):

Surface Roughness ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Local Heating ◽

Wire Electrical Discharge Machining ◽

Machining Parameters ◽

Good Surface ◽

Good Surface Finish ◽

Wedm Process

Wire electrical discharge machining (WEDM) is a thermal process in which the workpiece and the wire (tool) experience an intense local heating in the discharge channel. The high power density results in the erosion of a part of the material from both electrodes by local melting and vaporization. Whilst good surface finish and high material removal rate of the workpiece is a major requirement, the effect of EDM machining factors on these requirements cannot be overlooked. This study investigate the effect of two different machining methods of dry and wet WEDM process as well as the effect of on-time and voltage on the surface roughness of the workpiece. The machining factors used for this study are the pulse current, on-time and voltage. The results of the effect of the two machining methods on the responses are investigated and reported in this paper.

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