Investigating affecting parameters on surface roughness and metal removal rate in wire electrical discharge machining process

Abstract It is well known that electrical discharge machining can be used in the processing of nonconductive materials. In order to improve the efficiency of machining modern engineering materials, existing electrical discharge machines are constantly being researched and improved or developed. The current machining of non-conductive materials is limited due to the relatively low material removal rate and high surface roughness. A possible technological improvement of electrical discharge machining can be achieved by innovations of existing processes. In this paper, a new approach for machining zirconium oxide is presented. It combines electrical discharge machining with assisting electrode and powder-mixed dielectric. The assisting electrode is used to enable electrical discharge machining of nonconductive material, while the powder-mixed dielectric is used to increase the material removal rate, reduce surface roughness, and decrease relative tool wear. The response surface method was used to generate classical mathematical models, analyzing the output performances of surface roughness, material removal rate and relative tool wear. Verification of the obtained models was performed based on a set of new experimental data. By combining these latest techniques, positive effects on machining performances are obtained. It was found that the surface roughness was reduced by 18%, the metal removal rate was increased by about 12% and the relative tool wear was reduced by up to 6% compared to electrical discharge machining with supported electrode without powder.

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Surface roughness and material removal rate analyses of hard copper alloy in wire electrical discharge machining

Emerging Materials Research ◽

10.1680/jemmr.20.00088 ◽

2020 ◽

Vol 9 (3) ◽

pp. 730-737

Author(s):

Savas Evran

Keyword(s):

Surface Roughness ◽

Material Removal Rate ◽

Copper Alloy ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Wire Electrical Discharge Machining

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Wire Electrical Discharge Machining – High Speed VS Abrasive Waterjet - A Case Study

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.189-193.4245 ◽

2011 ◽

Vol 189-193 ◽

pp. 4245-4255

Author(s):

Shi Jin Zhang ◽

Yu Qiang Wu ◽

Yan Li Wang

Keyword(s):

Electrical Discharge ◽

High Speed ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Machining Process ◽

Abrasive Waterjet ◽

Wire Electrical Discharge Machining ◽

Technological Advancement ◽

Proper Selection ◽

Regular User

Technological advancement, on the one hand, made Electrical Discharge Machining (EDM) much faster. One example of that is the presence of Wire Electrical Discharge Machining – High Speed (WEDM-HS) machine, which makes the material removal rate as high as 80 . On the other hand, it also made Abrasive Waterjet (AWJ) achieve much better quality surface and tighter tolerance. As a result, these two types of machining process have converged to the point where they can complement one another quite nicely in selected applications. However, it does not mean user may pick any one for their applications. The proper selection not only decreases the manufacturing costs but also achieves better quality. This paper focuses on comparing WEDM-HS with AWJ by actually cutting a special designed sample. Through comparison from several aspects which include dimension precision, surface roughness, cost, cutting time and surface damage, a proper selection guidance for regular user has been provided.

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Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of Ti-6Al-4V Using Zinc Coated Brass Wire

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.592-594.416 ◽

2014 ◽

Vol 592-594 ◽

pp. 416-420 ◽

Cited By ~ 3

Author(s):

Singaravelu D. Lenin ◽

A. Uthirapathi ◽

Ramana Reddy P.S. Venkata ◽

Muthukannan Durai Selvam

Keyword(s):

Surface Roughness ◽

Electrical Discharge ◽

Metal Removal ◽

Electrical Discharge Machining ◽

Kerf Width ◽

Dielectric Fluid ◽

Wire Electrical Discharge Machining ◽

Pulse On Time ◽

Pulse Off Time ◽

Brass Wire

The present paper describes the influence of pulse-on-time on performance features such as Metal Removal Rate (MRR), Kerf width, Surface Roughness (SR) on cutting Titanium alloy (Ti-6Al-4V) in wire electrical discharge machining (WEDM) using zinc coated brass wire. The deionised water is used as dielectric fluid. The process parameters such as wire tension, wire speed, flushing pressure, discharge current, sparking voltage and pulse off time have kept constant at appropriate values throughout the experiment and the pulse on time is varied at nine different intervals. It was found that pulse-on-time is the most significant factor which greatly influences MRR, kerf width, and SR. It was also observed that taper at the end of cutting zone which is unavoidable occurrence for the machined part. This is due to the erosion of wire material. The surface roughness increases with increase in pulse on time also with higher rate of MRR.

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The influence of electrode infeed in finishing wire electrical discharge machining process on disks fir tree slot accuracy

Mechanik ◽

10.17814/mechanik.2018.10.161 ◽

2018 ◽

Vol 91 (10) ◽

pp. 915-917

Author(s):

Jan Burek ◽

Robert Babiarz ◽

Marcin Płodzień ◽

Jarosław Buk

Keyword(s):

Surface Roughness ◽

Inconel 718 ◽

Electrical Discharge ◽

Electrical Discharge Machining ◽

Machining Process ◽

Wire Electrical Discharge Machining ◽

Inconel 718 Alloy ◽

Shape Accuracy ◽

Finishing Machining

The article presents the effect of electrode infeed in finishing machining of disk fir tree slots made of Inconel 718 alloy on shape accuracy and surface roughness in WEDM (wire electrical discharge machining).

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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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surface roughness,metal removal Effect of Wire Diameter, Feeding Rate, Pulse (on/off) Time on Surface Roughness and Metal Removal Rate for Cr-Mo Steel (SCM425H) During Wire Electrical Discharge Machine (WEDM) Cutting Operation

Engineering and Technology Journal ◽

10.30684/etj.v38i6a.524 ◽

2020 ◽

Vol 38 (6A) ◽

pp. 854-860

Author(s):

Saad K. Shather ◽

Sami A. Hammood ◽

Noor Al-Huda A. Hussain ◽

Noor H. Hasson

Keyword(s):

Surface Roughness ◽

Electrical Discharge ◽

Feeding Rate ◽

Metal Removal ◽

Removal Rate ◽

Electrical Discharge Machine ◽

Wire Diameter ◽

Metal Removal Rate ◽

Discharge Machine ◽

Off Time

Increase the demand to produce complex shapes with high quality and dimensional accuracy such as production aerospace, cars, die sinking has been leading to increase the demand to use the non- traditional cutting operations such as wire electro-discharge machine (WEDM) rather than using the traditional operations. An idea to understand the effect of wire diameter, wire feed, pulsing (on/off) time on surface roughness, and metal removal rate of Cr-Mo steel during wire electrical discharge machining was investigated. Two Steel alloy samples with dimensions of (60 x50 x 20)mm were cut into four rectangular spaces with (5x10x20)mm at one side of each sample using wire cut (EDM) machine with a wire diameter of 0.25 mm and feeding rate 2 m/min for sample 1 and a 0.3 mm diameter and 3 m/min feeding rate for sample 2. Pulse (on, off) time was (110, 50), (112, 52), (115, 55), (116, 57) corresponds to space 1, space 2, space 3, and space 4 in both steel block. Surface roughness and metal removal rate measurements were estimated. The results showed that wire diameter, feeding rate, and pulse (on, off) time is proportional with metal removal rate, while reversed with surface roughness. The wire diameter of 0.3 mm and a feeding rate of 3m/min enhanced better surface quality and productivity. Pulse (on, off) time is the most effective parameter. Best duration time was recorded at the values (116, 57).

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Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/09544089211060722 ◽

2021 ◽

pp. 095440892110607

Author(s):

Sadananda Chakraborty ◽

Souren Mitra ◽

Dipankar Bose

Keyword(s):

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Ti6al4v Alloy ◽

Machining Process ◽

Wire Electrical Discharge Machining ◽

Powder Concentration ◽

Pulse Off Time ◽

Off Time

Precision machining characteristics with high-dimensional accuracy make the material more adaptable towards the applications. The present study employs the powder mixed wire electrical discharge machining process to machine Ti6Al4V alloy material. In spite of limited drawbacks and enhanced output in the powder mixed wire electrical discharge machining process, the present problem has been formulated for improving the machining efficiency of Ti6Al4V. The impact of suspended powder characteristics on responses, that is, material removal rate and surface roughness, is examined throughout the process. The current investigation also focuses on the interaction effect of machining constraints along with Al2O3 abrasive mixed dielectric to achieve economical machining output for the Ti6Al4V material. An effort has been presented to obtain optimal solutions using the different methodologies, namely response surface methodology, grey relation analysis, and particle swarm optimization. The study reveals that discharge energy is deeply influenced by the peak current and pulse off time followed by powder concentration in the powder mixed wire electrical discharge machining process. The maximum material removal rate of 6.628 mm3/min and average surface finish of 1.386 μm are the outcome of the present study for a set of optimal machining settings, that is, pulse off time ( Toff) of 7.247 μs, pulse on time ( Ton) of 30 μs, peak current ( Ip) of 2 A, and powder concentration of 4 g/L. Finally, the proposed model has been verified that the hybrid particle swarm optimization technique has the highest adequate capability to achieve maximum output. Thus, the approach offered an enhancement on performance measures of Ti6Al4V alloy in the powder mixed wire electrical discharge machining process.

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