EFFECT OF ELECTRODE MATERIAL ON CUT QUALITIES OF SHAPE MEMORY ALLOY DURING WEDM: A COMPARATIVE STUDY

2019 ◽  
Vol 27 (04) ◽  
pp. 1950136
Author(s):  
HIMADRI MAJUMDER ◽  
KALIPADA MAITY
Keyword(s):  
Micro Hardness ◽  
Process Variables ◽  
Machining Time ◽  
Five Factors ◽  
Series Of Experiments ◽  
Pulse On Time ◽  
Wedm Process ◽  
Different Levels ◽  
Fesem Micrographs ◽  
Brass Wire

This paper compares some of the vigorous machinability characteristics of SMA-Nitinol during WEDM process using uncoated and zinc coated brass wire electrodes. A series of experiments were regulated based on Taguchi’s L[Formula: see text] orthogonal array with an objective of unveiling the benefits of using coated brass wire electrodes in comparison to uncoated counterparts. Five factors, namely pulse-on time ([Formula: see text]), discharge current ([Formula: see text]), wire tension (WT), wire speed (WS) and flushing pressure (FP), were considered, each at three different levels to scrutinize four responses, viz. surface roughness (Ra), kerf width (KW), machining time (MT) and micro-hardness ([Formula: see text]h). It was perceived that zinc-coated brass wire was more preferable to get favorable responses like Ra, KW and [Formula: see text]h when compared with brass wire counterparts. FESEM micrographs also revealed that micro and large cracks, wide craters, recast layer were more prominent on the WEDMed surface of brass wire compared to zinc-coated brass wire. Use of zinc-coated brass wire electrode significantly improves the machinability of the selected work material within the specified range of process variables.

scholarly journals Taguchi Optimization In Machining Inconel 600 With WEDM Process Using Cryogenically Treated Brass Wire

2021 ◽  
Vol 309 ◽  
pp. 01110
Author(s):  
K. Satyanarayana ◽  
B Ramya Krishna ◽  
M. Bhargavi ◽  
R. Eswari Vasuki ◽  
K. Raj Kiran
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Inconel 600 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time ◽  
Brass Wire

Wire electric discharge machining (WEDM) is one amongst the unconventional machining processes which might cut all kinds of shapes with an accuracy of +/−0.001mm. It will cut the materials that conduct electricity and can even cut the exotic metals like tungsten carbide, Hastelloy, Inconel etc. In the present work, machining on Inconel 600 by wire EDM with cryogenically treated brass wire is performed. Brass wire of 0.25mm diameter has been cryogenically treated at −90°C, −100°C and −110°C temperatures separately. An Experimental layout is designed as per Taguchi’s L-9 orthogonal array and experiments were conducted by varying machining parameters viz. Voltage, Pulse ON time and Pulse OFF time. The machining parameters are optimized using Taguchi’s methodology for minimum surface roughness and maximum metal removal rate (MRR). A Mathematical regression model for surface roughness and MRR is generated with the help of regression analysis. Through the Analysis of Variance (ANOVA) It was found that for MRR, pulse on time is the foremost contributing factor with 32.69% and for surface roughness, pulse off time is the foremost contributing factor with 23.59%.

Electrical Discharge Machining of Nickel-Based Super Alloy

2012 ◽  
Vol 581-582 ◽  
pp. 378-381 ◽  
Author(s):  
Li Li ◽  
R.G. Hou ◽  
Z.W. Sima
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Surface Characteristic ◽  
Micro Hardness ◽  
Hardness Tests ◽  
Pulse On Time ◽  
Wedm Process ◽  
Machining Characteristics ◽  
Super Alloy

This paper presents an experimental investigation of the machining characteristics of IN718 nickel-based super alloy in wire electrical discharge machining (WEDM) process. During experiments, parameters of discharge current and pulse on time were changed to explore the effect on various aspects of the surface characteristic. Scanning electron microscopy (SEM), surface roughness and micro hardness tests were performed. Experimental results reveal that the surface roughness will increase with the increasing of current and pulse duration. Micro hardness tests show there is no hard phenomenon.

Empirical Modeling of High-Speed WEDM Finishing in Gas

2012 ◽  
Vol 486 ◽  
pp. 503-508 ◽  
Author(s):  
Yu Mei Lu ◽  
Tong Wang ◽  
Chao Qun Wang ◽  
Cheng Wen Wang
Keyword(s):  
Regression Model ◽  
High Speed ◽  
High Reliability ◽  
Cutting Speed ◽  
Process Models ◽  
Empirical Modeling ◽  
Pulse Interval ◽  
Five Factors ◽  
Pulse On Time ◽  
Wedm Process

This paper aims at getting the finishing process models in HS-WEDM in gas. Using cutting speed and the roughnessRaas index, the five factors of pulse-on time, peak current, offset, pulse interval ratio and worktable feed were chosen in dry finishing. The effects of the five factors and their interaction on cutting speed and the Surface roughnessRaand empirical models for cutting speed and roughnessRawere developed by performing a designed experiment based on the central composite design (CCD) experiments, significant order influencing cutting speed and roughness were found. The results of the verification test show thatRaRegression Model and Cutting Speed Regression Model have high reliability, and can achieve significant prediction effect, more accurate mathematical models are provided for the further HS-WEDM process research.

MICROSTRUCTURAL ANALYSIS OF TITANIUM ALLOY GEAR USING WEDM PROCESS

2018 ◽  
Vol 25 (06) ◽  
pp. 1850112
Author(s):  
K. D. MOHAPATRA ◽  
S. K. SAHOO
Keyword(s):  
Titanium Alloy ◽  
Microstructural Analysis ◽  
Machining Process ◽  
Material Surface ◽  
Work Piece ◽  
The Wire ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Brass Wire

The present paper deals with the microstructural analysis of Titanium alloy gears (Ti-6Al-4V) by wire EDM process machined by both brass and combii wire electrodes. The objective of the present paper is to investigate the surface characteristics of both the wires and to analyze the effects on the material surface. Two types of wires i.e. brass wire and combii wires were selected for the analysis and the experiment was carried out using a full factorial design having 81 sets of combinations. Pulse on time, pulse off time, wire feed rate and servo voltage were taken as the input parameters and kerf width, material removal rate, surface roughness and wire wear rate were taken as the response parameters for the experiment. The output responses were optimized by using MOORA-based GA methodology. Microstructural analysis was carried out at the optimized settings obtained by two types of wires to investigate the surface defects and analysis present in the work-piece and the wire. The microstructural analysis for the brass wire was investigated depicting the formation of micro cracks, dendrites, spherical globules, melted debris, recast layer and wire rupture on the wire surface after the machining operation. Similarly the microstructural analysis for the combii wire was analyzed out depicting the formation of wire rupture, melted debris, spherical globules, cracks and wire burr formed on the wire after the machining process. The optical image confirms that brass wire has more rupture than the combii wire due to the spark efficiency of brass wire being more than the combii wire. The EDS of material and the wires have been analyzed depicting the presence of element and weight % in the sample. From the performance analysis and the present experiment attained, it was concluded that the combii wire is more desirable to produce high quality gears than the brass wires at the obtained optimized settings of the response.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

EFFECT OF ABRASIVE TYPE ON THE SURFACE ROUGHNESS AND MRR IN MAF OF AISI 304 STEEL

2021 ◽  
Author(s):  
MAHMUT ÇELIK ◽  
HAKAN GÜRÜN ◽  
ULAŞ ÇAYDAŞ
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Three Dimensional ◽  
Steel Plates ◽  
304 Stainless Steel ◽  
Average Surface Roughness ◽  
Machining Time ◽  
Aisi 304 ◽  
Average Surface ◽  
Different Levels

In this study, the effects of experimental parameters on average surface roughness and material removal rate (MRR) were experimentally investigated by machining of AISI 304 stainless steel plates by magnetic abrasive finishing (MAF) method. In the study in which three different abrasive types were used (Al2O3, B4C, SiC), the abrasive grain size was changed in two different levels (50 and 80[Formula: see text][Formula: see text]m), while the machining time was changed in three different levels (30, 45, 60[Formula: see text]min). Surface roughness values of finished surfaces were measured by using three-dimensional (3D) optical surface profilometer and surface topographies were created. MRRs were measured with the help of precision scales. The abrasive particles’ condition before and after the MAF process was examined and compared using a scanning electron microscope. As a result of the study, the surface roughness values of plates were reduced from 0.106[Formula: see text][Formula: see text]m to 0.028[Formula: see text][Formula: see text]m. It was determined that the best parameters in terms of average surface roughness were 60[Formula: see text]min machining time with 50[Formula: see text][Formula: see text]m B4C abrasives, while the best result in terms of MRR was taken in 30[Formula: see text]min with 50[Formula: see text][Formula: see text]m SiC abrasives.

Machining Characteristics Estimation in WEDM Process While Machining Titanium Grade-2 Material Using ANN

2020 ◽  
Author(s):  
Prathik Jain Sudhir ◽  
Ravindra Holalu Venkatadas ◽  
Ugrasen Gonchikar
Keyword(s):  
Process Parameters ◽  
Machining Process ◽  
Electrode Wear ◽  
Training Set ◽  
Hard Materials ◽  
Titanium Grade ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Machining Characteristics

Abstract Wire Electrical Discharge Machining (WEDM) provides an effective solution for machining hard materials with intricate shapes. WEDM is a specialized thermal machining process is capable to accurately machining parts of hard materials with complex shapes. However, selection of process parameters for obtaining higher machining efficiency or accuracy in wire EDM is still not fully solved, even with the most up-to-date CNC WED machine. The study presents the machining of Titanium grade 2 material using L’16 Orthogonal Array (OA). The process parameters considered for the present work are pulse on time, pulse off time, current, bed speed, voltage and flush rate. Among these process parameters voltage and flush rate were kept constant and the other four parameters were varied for the machining. Molybdenum wire of 0.18mm is used as the electrode material. Titanium is used in engine applications such as rotors, compressor blades, hydraulic system components and nacelles. Its application can also be found in critical jet engine rotating and airframes components in aircraft industries. Firstly optimization of the process parameters was done to know the effect of most influencing parameters on machining characteristics viz., Surface Roughness (SR) and Electrode Wear (EW). Then the simpler functional relationship plots were established between the parameters to know the possible information about the SR and EW. This simpler method of analysis does not provide the information on the status of the material and electrode. Hence more sophisticated method of analysis was used viz., Artificial Neural Network (ANN) for the estimation of the experimental values. SR and EW parameters prediction was carried out successfully for 50%, 60% and 70% of the training set for titanium material using ANN. Among the selected percentage data, at 70% training set showed remarkable similarities with the measured value then at 50% and 60%.

Surface morphology evaluation of hardened HSLA steel using cryogenic-treated brass wire in WEDM process

2019 ◽  
Vol 104 (9-12) ◽  
pp. 4445-4455 ◽  
Author(s):  
Waseem Tahir ◽  
Mirza Jahanzaib ◽  
Wasim Ahmad ◽  
Salman Hussain
Keyword(s):  
Surface Morphology ◽  
Hsla Steel ◽  
Wedm Process ◽  
Brass Wire

Influence of Input Factors on Material Removal Rate in PMEDM Cylindrical Shaped Parts with Silicon Carbide Powder Suspended Dielectric

2020 ◽  
Vol 861 ◽  
pp. 129-135 ◽  
Author(s):  
Manh Cuong Nguyen ◽  
Luu Anh Tung ◽  
Bui Thanh Danh ◽  
Nguyen Van Cuong ◽  
Tran Thi Hong ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Carbide Powder ◽  
Powder Concentration ◽  
Five Factors ◽  
Cylindrical Parts ◽  
Pulse On Time ◽  
Pulse Off Time

This work is done to determine the effects of the input factors of powder mixed electrical discharge machining (PMEDM) process on the material removal rate (MRR). In the study, the workpiece is cylindrical parts made from 90CrSi alloy steel. Also, five factors containing the pulse on time Ton, the powder concentration Cp, the pulse off time Toff, the pulse current IP, and the server voltage SV were discovered to find their impact on MRR. In addition, the Taguchi method and ANOVA analysis were used to design experiment and analyze the results. In addition, an optimal model of the MRR was introduced. Also, the model has been well verified by comparison with testing, and so it can be used for further studies in the PMEDM process.

Investigation of Micro-Cracks Susceptibility on Machined Pure Titanium Surface in WEDM Process

2016 ◽  
Vol 16 (2) ◽  
pp. 123-139 ◽  
Author(s):  
Anish Kumar ◽  
Vinod Kumar ◽  
Jatinder Kumar
Keyword(s):  
Titanium Dioxide ◽  
Crack Formation ◽  
Research Work ◽  
Pure Titanium ◽  
Machined Surface ◽  
X Ray ◽  
Micro Cracks ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

AbstractThis research work presents a comprehensive and quantitative analysis of micro-crack formation, in terms of length and number of micro-cracks formed on the machined surface of pure titanium. The effect of processing parameters on micro-crack formation was studied through scanning electron microscope. The results indicate that the micro-crack formation is the best represented in terms of average crack length. Statistical analysis of the results shows that pulse on time, pulse off time and peak current significantly deteriorate the microstructure of machined surfaces which produces the deeper, wider globules of debris and micro cracks. The compounds like titanium dioxide (rutile) (TiO2), (TiO0.325), Ti2O3, Ilmenite (Fe2Ti4O), titanium carbides (TiC) and copper titanium dioxide (Cu3TiO4) were formed due to phase transformations that were analyzed through X-ray diffraction and energy dispersive X-ray method.

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