Wire electrical discharge machining of AZ91 magnesium alloy; investigation of effect of process input parameters on performance characteristics

In this study, the appropriate input parameters for achieving minimum surface roughness and high material removal rate are selected for wire electrical discharge machining of cold-work steel 2601. Mathematical modeling acquired by experimental result analysis is used to find the relation between input parameters including electrical current, gap voltage, open-circuit voltage and pulse-off time and output parameters. Subsequently, with exploitation of variance analysis, importance and effective percentages of each parameter are studied. The combination of optimum machining parameters is acquired using the analysis of ratios of signal-to-noise. Finally, according to multiple-objective optimization, outputs acquired from Non-dominated Sorting Genetic Algorithm led in achieving appropriate models. The optimization results showed suggested method has a high performance in problem solving.

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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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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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A Hybrid Approach for Process Optimization in Taper Cutting Operation Using Wire Electrical Discharge Machining

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.619.83 ◽

2014 ◽

Vol 619 ◽

pp. 83-88 ◽

Cited By ~ 3

Author(s):

Bijaya Bijeta Nayak ◽

Siba Sankar Mahapatra

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Hybrid Approach ◽

Angular Error ◽

Wire Electrical Discharge Machining ◽

Ann Model ◽

Marquardt Algorithm ◽

Input Parameters ◽

Cutting Operation ◽

Wedm Process

Angular error is a major concern for the tool engineers during the taper cutting operation in wire electrical discharge machining (WEDM) process. Due to the complexity and non-linearity involved in the process, it is difficult to obtain good functional relationship between responses and process parameters. To address this issue, the present study proposes artificial neural network (ANN) model to determine the relationship between input parameters and output response. Bayesian regularization is adopted for selection of optimum network architecture because of its ability to fix number of network parameters irrespective of network size. Levenberg-Marquardt algorithm has been used to train the ANN model and the resulting network has good generalization capability minimizing the chance of over fitting. The model is developed based on the data obtained from a laboratory scale experimental set up. A set of six important input parameters such as part thickness, taper angle, pulse duration, discharge current, wire speed and wire tension is chosen to study the tapering operation in WEDM. Finally, a recent meta-heuristic approach known as Bat algorithm is used to suggest the optimum parametric combination for minimizing the angular error during taper cutting process in WEDM.

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Comparison of optimization techniques of input parameters in wire electrical discharge machining

International Journal of Latest Trends in Engineering and Technology ◽

10.21172/1.841.26 ◽

2017 ◽

Vol 8 (41) ◽

Keyword(s):

Electrical Discharge ◽

Electrical Discharge Machining ◽

Optimization Techniques ◽

Wire Electrical Discharge Machining ◽

Input Parameters

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Optimization of Process Parameters for Minimum Surface Roughness in Wire Electrical Discharge Machining of AISI 1045 Steel Using Taguchi Method

International Journal for Research in Applied Science and Engineering Technology ◽

10.22214/ijraset.2021.38537 ◽

2021 ◽

Vol 9 (10) ◽

pp. 989-997

Author(s):

Rouhan Rafiq

Keyword(s):

Surface Roughness ◽

Process Parameters ◽

Material Removal Rate ◽

Electrical Discharge ◽

Material Removal ◽

Electrical Discharge Machining ◽

Removal Rate ◽

Wire Electrical Discharge Machining ◽

Input Parameters ◽

Pulse On Time

Abstract: One of the important non-traditional machining processes is Wire Electrical Discharge Machining, used for machining difficult to machine materials like composites and inter-metallic materials. WEDM involves complex physical and chemical process including heating and cooling. Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact resistance are increasing. The WEDM satisfy the present demands of the manufacturing industries such as better finish, low tolerance, higher production rate, miniaturization etc. The consistent quality of parts being machined in WEDM is difficult because the process parameters cannot be controlled effectively. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researcher and practicing engineers for a very long time. The objective of the present study was to experimentally investigate the effects of various Wire Electrical Discharge Machining variables on Surface Roughness and Material Removal Rate of AISI 1045 using ANOVA method. Taguchi’s L18 Orthogonal Array was used to conduct experiments, which correspond to randomly chosen different combination of process parameters: wire type, pulse on time, pulse off time, peak current, servo voltage, wire feed rate, flushing pressure each to be varied in three different levels. The surface roughness and material removal rate were selected as output responses for the present investigation. The effect of all the input parameters on the output responses have been analyzed using analysis of variance (ANOVA). The effect of variation in input parameters has been studied on the output responses. Plots of S/N ratio have been used to determine the best relationship between the responses and the input parameters. In other words, the optimum set of input parameters for minimum surface roughness and maximum material removal rate were determined. It has been found that wire type, pulse on time are most significant factors for surface roughness and wire type, pulse on time, pulse off time, wire feed rate are most significant factors for material removal rate. Keywords: Input Parameters, Wire Electric Discharge Machining, ANOVA, Taguchi

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