scholarly journals Investigating the influence of WEDM process parameters in machining of hybrid aluminum composites

2020 ◽  
Vol 29 ◽  
pp. 2633366X2096313
Author(s):  
Amresh Kumar ◽  
Neelkant Grover ◽  
Alakesh Manna ◽  
Jasgurpreet Singh Chohan ◽  
Raman Kumar ◽  
...  
Keyword(s):  
Process Parameters ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Casting Process ◽  
Stir Casting ◽  
Matrix Composites ◽  
Input Process ◽  
Spark Gap ◽  
Wedm Process

This article presents an experimental investigation to assess the influence of input process parameters of machinability of wire electrical discharge machining (WEDM) process for machining of triple-reinforced silicon carbide, graphite, and iron oxide hybrid aluminum (Al-6061) metal matrix composites. The composite work specimens, developed using stir casting process, have been processed through WEDM process by adopting a statistically controlled design of experimentation approach. Furthermore, analysis of variance and regression analysis have been performed to understand the influence of the input process parameters on material removal rate (MRR) and spark gap (SG) width. The statistical analysis highlighted the improvements in MRR and SG by 33.72% and −27.28%, respectively, upon adopting the suggested optimized range of input process parameters. Further, the morphology of the machined composite surfaces has also been studied using scanning electron microscopy and energy dispersive spectroscopy to report the phenomenon of formation of recast layer.

Investigation of the Spark Cycle Effect on Material Removal Rate in Wire Electrical Discharge Machining

Manufacturing ◽  
2003 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Short Circuit ◽  
Wire Electrical Discharge Machining ◽  
Time Duration ◽  
Edm Process

The development of new, advanced engineering materials and the needs for precise and flexible prototype and low-volume production have made wire electrical discharge machining (EDM) an important manufacturing process to meet such demand. This research investigates the effect of spark on-time duration and spark on-time ratio, two important EDM process parameters, on the material removal rate (MRR) and surface integrity of four types of advanced material: porous metal foams, metal bond diamond grinding wheels, sintered Nd-Fe-B magnets, and carbon-carbon bipolar plates. An experimental procedure was developed. During the wire EDM, five types of constraints on the MRR due to short circuit, wire breakage, machine slide speed limit, and spark on-time upper and lower limits have been identified. An envelope of feasible EDM process parameters is created and compared across different work-materials. Applications of such process envelope to select process parameters for maximum MRR and for machining of micro features are presented.

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.

Sensitivity analysis and optimization of EDM process parameters

2019 ◽  
Vol 43 (1) ◽  
pp. 13-25 ◽  
Author(s):  
Uvaraja Ragavendran ◽  
Ranjan Kumar Ghadai ◽  
Akash Kumar Bhoi ◽  
Manickam Ramachandran ◽  
Kanak Kalita
Keyword(s):  
Sensitivity Analysis ◽  
Process Parameters ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Significance ◽  
Empirical Models ◽  
Optimization Techniques ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining (EDM) is a broadly used nonconventional material removal process for the machining of conductive work material irrespective of their hardness. In this article, empirical models for material removal rate (MRR) and surface roughness (Ra) of the workpiece are developed based on the extensive experiments performed on a special steel (WP7V) workpiece using a copper electrode. To account for the various parameters, an experimental design based on response surface methodology (RSM) is conducted considering three different factors namely — current, pulse-on-time, and pulse-off-time, each having three different levels. Analysis of variance (ANOVA) is conducted to test the statistical significance of the proposed empirical models. It is essential to determine the relationship and significance of input–output variation. Thus a sensitivity analysis is conducted. The interaction effect of input variables is also studied. Two different state-of-art optimization techniques, namely genetic algorithm (GA) and particle swarm optimization (PSO), are applied to predict the optimal combination of process parameters. Finally, multi-objective optimization is also carried out to simultaneously maximize MRR while minimizing Ra.

Multi-Objective Optimization of PMEDM Process of 90CrSi Alloy Steel for Minimum Electrode Wear Rate and Maximum Material Removal Rate with Silicon Carbide Powder

2021 ◽  
Vol 1018 ◽  
pp. 51-58
Author(s):  
Tran Thi Hong ◽  
Nguyen Van Cuong ◽  
Bui Thanh Danh ◽  
Le Hong Ky ◽  
Nguyen Hong Linh ◽  
...  
Keyword(s):  
Silicon Carbide ◽  
Alloy Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Carbide Powder ◽  
Electrode Wear ◽  
Silicon Carbide Powder

This study aims to minimize electrode wear (EW) and maximize material removal rate (MRR) in powder mixed electrical discharge machining (PMEDM) process of 9CrSi alloy steel with silicon carbide powder. To achieve these objectives, Taguchi method and Grey Relational Analysis (GRA) are applied to optimize one two-level and four three-level PMEDM process parameters, including Ton, Toff, CP, IP and SV in eighteen experiments based on an orthogonal array L18 (21 and 43). Results have provided a set of optimal PMEDM process parameters in which Ton has the strongest effect on SW and MRR while that of CP is insignificant. The obtained minimum EW and maximum MRR have been verified and proven by a PMEDM experiment using optimal process parameters. The proposed method can be further applied to optimize other PMEDM process parameters for different objectives.

Multi-Response Optimization of CNC WEDM Process Parameters for Machining Titanium Alloy Ti 6AI-4V Using Response Surface Methodology (RSM)

2014 ◽  
Vol 541-542 ◽  
pp. 354-358 ◽  
Author(s):  
C. Nandakumar ◽  
B. Mohan
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Titanium Alloy ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Response Optimization ◽  
Wedm Process

This research deals with the multi-response optimization of CNC WEDM process parameters for machining titanium alloy Ti 6AI-4V using Response Surface Methodology (RSM) to achieve higher Material Removal Rate (MRR) and lower surface roughness (Ra). The process parameters of CNC WEDM namely pulse-on time (TON), pulse-off time (TOFF) and wire feed rate (WF) were optimized to study the responses in terms of material removal rate and surface roughness. The surface plot and the contour plots were generated between the process parameters and the responses using MINITAB software. The results show that the Response surface methodology (RSM) is a powerful tool for providing experimental diagrams and statistical-mathematical models to perform the experiments appropriately and economically.

A Study of the Material Removal Rate of Electrical Discharge Machining of Particle Reinforced Metal Matrix Composites with Concavo-Convex Electrode

2011 ◽  
Vol 480-481 ◽  
pp. 294-299
Author(s):  
Jiang Wen Liu ◽  
T.M. Yue ◽  
Zhong Ning Guo ◽  
Z. Y. Wan ◽  
G.Y. Liu
Keyword(s):  
Material Removal Rate ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Processing Condition ◽  
Matrix Composites ◽  
Particulate Reinforced ◽  
Stable Processing

A new concavo-convex electrode has been designed and fabricated. And an analysis of the electrical discharge machining (EDM) of a particulate reinforced metal matrix composite this new electrode was conducted in this study. The material removal rate (MRR) of new electrode and normal electrode are compared in different applied voltage and duty cycle conditions. It was found that EDM with this new electrode can accelerate the debris discharge during machining so that it has a higher MRR compared to the case where a normal electrode was employed. Moreover, by studying the waveforms, it could confirm that a stable processing condition can be obtained by employing the new electrode. The experiment results reveal that it is a feasible and effective way to machine MMCs by employing this new electrode.

scholarly journals Synthesis and Characterization of Mechanical Properties and Wire Cut EDM Process Parameters Analysis in AZ61 Magnesium Alloy + B4C + SiC

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3689
Author(s):  
Thanikodi Sathish ◽  
Vinayagam Mohanavel ◽  
Khalid Ansari ◽  
Rathinasamy Saravanan ◽  
Alagar Karthick ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Stir Casting ◽  
Electric Discharge Machining ◽  
Az61 Magnesium Alloy

Wire Cut Electric Discharge Machining (WCEDM) is a novel method for machining different materials with application of electrical energy by the movement of wire electrode. For this work, an AZ61 magnesium alloy with reinforcement of boron carbide and silicon carbide in different percentage levels was used and a plate was formed through stir casting technique. The process parameters of the stir casting process are namely reinforcement %, stirring speed, time of stirring, and process temperature. The specimens were removed from the casted AZ61 magnesium alloy composites through the Wire Cut Electric Discharge Machining (WCEDM) process, the material removal rate and surface roughness vales were carried out creatively. L 16 orthogonal array (OA) was used for this work to find the material removal rate (MRR) and surface roughness. The process parameters of WCEDM are pulse on time (105, 110, 115 and 120 µs), pulse off time (40, 50, 60 and 70 µs), wire feed rate (2, 4, 6 and 8 m/min), and current (3, 6, 9 and 12 Amps). Further, this study aimed to estimate the maximum ultimate tensile strength and micro hardness of the reinforced composites using the Taguchi route.

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

Crystals ◽  
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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