Enhancement of machining and surface quality of quaternary alloyed NiTiCuZr shape memory alloy through ultrasonic vibration coupled WEDM

2021 ◽  
pp. 146442072110582
Author(s):  
C Balasubramaniyan ◽  
K Rajkumar ◽  
S Santosh
Keyword(s):  
Surface Roughness ◽  
Shape Memory ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Frequency ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

NiTiCuZr shape memory alloys (SMA) outperform ternary and binary SMA alloys in terms of functional fatigue and higher temperature performance due to their high cyclic stability and transformation temperatures. Owing to the impairment of the shape memory effect during processing, it is difficult to select a manufacturing process for obtaining design functionality with the required dimensions and surface roughness. In this work, a high-temperature NiTiCuZr SMA was machined using an ultrasonic vibration assisted wire electric discharge machine (USV-WEDM). The machining was conducted using various parameters with a constant ultrasonic vibration of 20 kHz provided on a wire-electrode to evaluate surface roughness (Ra) and material removal rate (MRR). Scanning Electron Microscope (SEM) and Energy Dispersive X-Ray analysis (EDX) were utilized to examine the surface integrity and chemical composition of the machined surfaces. MRR increased by 62% with a steady increase in pulse-on time ( Ton) and applied current ( I), whereas increasing levels of parameters such as pulse-off time ( Toff) and servo voltage (SV) reduced surface roughness ( Ra) by 69%. The results reveal that tool vibration at ultrasonic frequency reduces the surface roughness and improves the material removal rate of the machined NiTiCuZr SMA as compared to that of non-ultrasonic assisted machining conditions. SEM-EDX investigation reveals that the formation of re-solidification and oxide layers during NiTiCuZr machining at high machining parameters results in increased hardness and surface roughness. USV-WEDM is a suitable process for machining SMA alloy without adversely impacting SMA properties.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

scholarly journals A Study on Optimization of Process Parameters in Machining of Bronze using Wire-EDM

2021 ◽  
pp. 484-493
Author(s):  
Gajanan Kamble ◽  
Dr. N. Lakshamanaswamy ◽  
Gangadhara H S ◽  
Sharon Markus ◽  
N. Rajath
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time

Wire cut electrical discharge machining (WEDM) is a hybrid manufacturing technology which enables machining of all engineering materials. This research article deals with investigation on Optimization of the Process Parameters of the wire cut EDM of Bronze material of dimension (80*80*40) in mm. Material removal rate, Surface roughness and Kerf width were studied against the process parameters such as Pulse on time(TON), Pulse off time (TOFF) and Current(IP). The machining parameters for wire EDM were optimized for achieving the combined objectives. As there are three input parameters 27 experiments is carried out and full factorial is used. Optimized parameters were found using (ANOVA) and the error percentage can be validated and parameter contribution for the Material removal rate (MRR) and Surface roughness were found.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

Nano Graphite Powder Assisted Electric Discharge Machining Characteristics of ZM21 Magnesium Alloy

2015 ◽  
Vol 787 ◽  
pp. 406-410
Author(s):  
S. Santosh ◽  
S. Javed Syed Ibrahim ◽  
P. Saravanamuthukumar ◽  
K. Rajkumar ◽  
K.L. Hari Krishna
Keyword(s):  
Magnesium Alloy ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Electric Discharge Machining ◽  
Zm21 Magnesium Alloy ◽  
Pulse On Time ◽  
Pulse Off Time

Magnesium alloys are used in many applications, particularly in orthopaedic implants are very difficult to machine by conventional processes because of their complex 3D structure and limited slip system at room temperature. Hence there is an inherent need for alternative processes for machining such intricate profiles. Electric Discharge Machining is growing rapidly in tool rooms, die shops and even in general shop floors of modern industries to facilitate complex machining for difficult-to-machine materials and provide better surface integrity. Therefore, the use of electric discharge machining on ZM21 magnesium alloy is attempted in this paper. Nanographite powder is added for machining zone to enhance the electrical conductivity of EDM oil by way it improves the machining performance. Machining parameters such as the current, pulse on time and pulse off time were process parameters to explore their effects on the material removal rate and tool wear rate. It is observed that, an increased material removal rate was due to the enhanced electrical and thermal conductivity of the EDM oil.

scholarly journals Tool Wear Rate Prediction by using Optimization Techniques

2019 ◽  
Vol 9 (2) ◽  
pp. 1271-1277
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Machining Process ◽  
Machining Parameters ◽  
Tungsten Carbides ◽  
Electro Discharge Machining ◽  
Pulse On Time

Electro discharge machining is a non-traditional machining process used for machining hard-to-machine materials, such as various grades of titanium alloys, heat-treated alloy steels, composites, tungsten carbides, and so forth. These materials are hard to machine with customary machining procedures like drilling, milling and hence electro-discharge machining is used to machine such materials to get better quality and efficiency. These materials are generally utilized in current industries like die making industries, aeronautics, nuclear industries, and medical fields. This type of machining is thermalbased, and machining takes place due to repetitive electric sparks that generate between workpiece and tool. Both tools and workpieces are inundated in a dielectric liquid, which has two primary functions. In the first place, it behaves like a medium between the work metal and the tool. Second, it is a flushing agent to expel the machined metal from the machined zone. Machining parameters like a pulse on time, current, wire feed the tool and gap voltage affect the output responses like surface roughness and material removal rate. The material removal rate is a significant parameter that determines machining efficiency. Surface roughness is also a vital parameter that decides machining quality. A lot of research has been conducted to determine the optimum parameters for obtaining the best results. In the present work, a comprehensive review of different types of EDM and the effect of various machining parameters on the surface roughness, material removal rate, and other response parameters has been done.

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

2018 ◽  
Vol 28 ◽  
pp. 55-66 ◽  
Author(s):  
Kuldeep Singh ◽  
Khushdeep Goyal ◽  
Deepak Kumar Goyal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Tool Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

Statistical analysis of material removal rate and surface roughness in electrical discharge turning of titanium alloy (Ti-6Al-4V)

2016 ◽  
Vol 232 (9) ◽  
pp. 1603-1614 ◽  
Author(s):  
Vikas Gohil ◽  
Yogesh M Puri
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Machining Parameters ◽  
Peak Current ◽  
Pulse On Time

Electrical discharge turning is a unique form of electrical discharge machining process, which is being especially developed to generate cylindrical forms and helical profiles on the difficult-to-machine materials at both macro and micro levels. A precise submerged rotating spindle as a work holding system was designed and added to a conventional electrical discharge machine to rotate the workpiece. A conductive preshaped strip of copper as a forming tool is fed (reciprocate) continuously against the rotating workpiece; thus, mirror image of the tool is formed on the circumference of the workpiece. The machining performance of electrical discharge turning process is defined and influenced by its machining parameters, which directly affects the quality of the machined component. This study presents an investigation on the effects of the machining parameters, namely, pulse-on time, peak current, gap voltage, spindle speed and flushing pressure, on the material removal rate (MRR) and surface roughness (Ra) in electrical discharge turning of titanium alloy Ti-6Al-4V. This has been done by means of Taguchi’s design of experiment technique. Analysis of variance as well as regression analysis is performed on the experimental data. The signal-to-noise ratio analysis is employed to find the optimal condition. The experimental results indicate that peak current, gap voltage and pulse-on time are the most significant influencing parameters that contribute more than 90% to material removal rate. In the context of Ra, peak current and pulse-on time come up with more than 82% of contribution. Finally, the obtained predicted optimal results were verified experimentally. It was shown that the error values are all less than 6%, confirming the feasibility and effectiveness of the adopted approach.

Performance Measurement and Data Analysis of Material Removal Rate for Wire Cut Electro Discharge Machining Process

2011 ◽  
Vol 110-116 ◽  
pp. 1683-1690 ◽  
Author(s):  
Vishal Parashar ◽  
A. Rehman ◽  
J.L. Bhagoria
Keyword(s):  
Regression Analysis ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Performance Criteria ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing

In this paper, statistical and regression analysis of material removal rate using design of experiments is proposed for WEDM operations. Experimentation was planned as per Taguchi’s mixed orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, pulse OFF time, wire feed and dielectric flushing pressure. Stainless Steel grade 304L was selected as a work material to conduct the experiments. From experimental results, the material removal rate was determined for each machining performance criteria. Analysis of variance (ANOVA) technique was used to find out the variables affecting the material removal rate. Assumptions of ANOVA were discussed and carefully examined using analysis of residuals. Variation of the material removal rate with machining parameters was mathematically modeled by using the regression analysis method. The developed model was validated with a set of experimental data and appeared to be satisfactory. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method.

Experimental Analysis of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Method

2015 ◽  
Vol 799-800 ◽  
pp. 343-350
Author(s):  
Rahul Shukla ◽  
Brajesh Kumar Lodhi
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Kerf Width ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L9 Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (TON), pulse-off-time (TOFF), peak current (IP), and wire feed (WF) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.

scholarly journals Experimental Investigation of Edm Die Sinking Process Parameters on Aluminium Alloy 5083 Using Design of Experiment

2017 ◽  
Vol 4 (1) ◽  
pp. 138-144
Author(s):  
Wahaizad Safiei ◽  
Muhamad Ridzuan Radin Muhamad Amin
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Design Of Experiment ◽  
Material Removal ◽  
Removal Rate ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time

In this paper, the results of surface roughness (Ra) and material removal rate (MRR) are presented based on experimental studies of Electrical Discharge Machining (EDM) process parameters. Pulse ON time, pulse OFF time, peak current, gap voltage and jump speed are the selected input parameters and the experiments were conducted with Aluminium Alloy 5083 as a workpiece, copper as an electrode and the response variables are surface roughness (Ra) and material removal rate (MRR). Design of Experiment and Analysis of Variance (ANOVA) were applied to identify the optimum settings.The result shows that the significant factors for the value of surface roughness (Ra) and material removal rate (MRR) are pulses ON time and peak current.

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