scholarly journals Microstructural analysis and multi response optimization of WEDM of Inconel 825 using RSM based desirability approach

2019 ◽  
Vol 28 (1) ◽  
pp. 39-61 ◽  
Author(s):  
Pawan Kumar ◽  
Meenu Gupta ◽  
Vineet Kumar
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Desirability Approach ◽  
Unit Pulse ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wire Wear ◽  
Off Time ◽  
Wire Feed ◽  
Inconel 825

AbstractIncreasing demand of aerospace industry for more heat resistant and tough material have open up the possibility of the use of Inconel 825 for making of combustor casing and turbine blades. Because of its robust nature, Inconel 825 is a difficult-to-cut material with conventional methods. Wire-cut electrical discharge machining (WEDM), a non traditional method uses thermoelectric erosion principle to produce intricate shape and profiles of such difficult-to-cut material. In this study, various operating parameters of WEDM are optimized using desirability approach and microstructural behavior at optimum combinations was studied. Input parameters viz. pulse-on time, pulse-off time, peak current, spark gap voltage, wire tension, wire feed and performance has been measured in term of material removal rate, surface roughness and wire wear ratio. It has been observed that at 110 machine unit pulse-on time (Ton), 35 machine unit pulse-off time (Toff), 46 volt gap voltage (SV), 120 ampere peak current (IP), 11 machine unit wire tension (WT) and 5 m/min wire feed (WF), the values obtained for material removal rate (MRR), surface roughness (SR) and wire wear ratio (WWR) were 27.691mm2/min, 2.721 μmand 0.117 respectively. Scanning electron microscopy, energy dispersive spectrograph and X-ray diffraction analysis has also been carried out to study the surface characterization. Comparatively less numbers of cracks, pockmarks, craters, and pulled out material were found on work specimen surface and wire electrode surface under standardized conditions, thus maintaining the surface integrity of the machined surface.

scholarly journals Parameter Optimization of Wire EDM for H-13 Tool Steel

2018 ◽  
Vol 8 (01) ◽  
Author(s):  
Satish Giduturi ◽  
Ashok Kumar
Keyword(s):  
Tool Steel ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Wire Feed

Wire Electrical Discharge Machining (WEDM) is a widely accepted non-traditional material removal process used to manufacture components with intricate shapes and profiles. It is considered as a unique adaptation of the conventional EDM process, which uses an electrode to initialize the sparking process. H13 Hot Work Tool Steel has high hot tensile strength, hot wear-resistance and toughness. Good thermal conductivity and insensitiveness to hot cracking, making it suitable not only for hot die applications but also plastic moulds. In this study, it is found that most predominant factors for the maximum material removal rate which is 22.21 mm3/min are current which was found to be 200A and Pulse ON Time 125 µs, however rest four factors (voltage 20V, pulse off time 40µs, wire tension 8N and wire feed 7mm/min) has less impact as compare to the predominant factors. The most predominant factors for Minimum surface roughness which is 0.89µm are wire tension 10N, pulse on time 115µs and servo voltage 60V. However, rest three factors pulse off time 60 µs, peak current 140 A and wire feed 7mm/min has less impact as compare to the predominant factors.

scholarly journals Multi- Response Optimization of Wire EDM Process Parameter on Aluminium Alloy (5086)

2020 ◽  
Vol 10 (1) ◽  
pp. 224-229
Keyword(s):  
Aluminium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Control Parameter ◽  
Removal Rate ◽  
Response Optimization ◽  
High Pulse ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, the effect of process parameters on material removal rate during the machining of aluminium alloy (5086) with WEDM is studied. The four control parameter were selected i.e pulse on time (TON), pulse off time (TOFF), peak current (IP), and spark gap voltage (SV) to investigate their effects on material removal rate (MRR). Each control parameter had three levels. Total 27 experiments were done with a zinc coated brass wire of diameter 0.25 mm. Taguchi L9 orthogonal array technique was used for the experiment. ANOVA was used to find out the significance of control parameters and their contribution on MRR. It was found that maximum material removal rate was 41.52 mm3 /min which was due to high pulse on time and low pulse off time.

Influence of Process Parameters on Characteristics of Electrical Discharge Machining of PH17-4 Stainless Steel

2015 ◽  
Vol 14 (03) ◽  
pp. 189-202 ◽  
Author(s):  
V. Vikram Reddy ◽  
P. Madar Valli ◽  
A. Kumar ◽  
Ch. Sridhar Reddy
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In the present work, an investigation has been made into the electrical discharge machining process during machining of precipitation hardening stainless steel PH17-4. Taguchi method is used to formulate the experimental layout, to analyze the effect of each process parameter on machining characteristics and to predict the optimal choice for each electrical discharge machining process parameters namely, peak current, pulse on time and pulse off time that give up optimal process performance characteristics such as material removal rate, surface roughness, tool wear rate and surface hardness. To identify the significance of parameters on measured response, the analysis of variance has been done. It is found that parameters peak current and pulse on time have the significant affect on material removal rate, surface roughness, tool wear rate and surface hardness. However, parameter pulse off time has significant affect on material removal rate. Confirmation tests are conducted at their respective optimum parametric settings to verify the predicted optimal values of performance characteristics.

scholarly journals The analysis of material removal rate of WEDM miniature gears

2021 ◽  
Vol 41 (3) ◽  
Author(s):  
Ashish Goyal ◽  
Vyom Singh ◽  
Abhishek Patel
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Spur Gear ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

Gear fabrication in wire electrical discharge machining (WEDM) plays an important role in manufacturing industries. This paper describes the analysis and optimization of process parameters for the fabrication of spur gear on brass spur gear on brass workpiece (10cmx15cmx6mm) material by wire EDM process. The experiments were performed by using the design of experiment (DoE) approach and the material removal rate (MRR) was analyzed by response surface methodology technique. The effect of input parameters i.e. pulse on time, pulse off time and feed rate on MRR has been investigated. The surface geometry of the gears has been analysed by the Scanning Electron Microscopy (SEM). This study found that 0.4 μs for pulse on time, 60 μs for pulse-off time and 6 mm/min for feed rate provides improved material removal rate. The analysis of variance shows that pulse on time and feed rate are the significant parameters for the wire EDM process. The SEM image exhibits the capability of WEDM to machined miniature gear with a uniform distribution of regular-shaped craters and defect-free flank surface.

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.

Electric Discharge Machining of Cryo-Treated NiTi Alloys

2015 ◽  
Vol 787 ◽  
pp. 366-370 ◽  
Author(s):  
Vaibhav Gaikwad ◽  
Vijaykumar S. Jatti ◽  
T.P. Singh
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Workpiece Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Conventional Machining

NiTi alloys possess superior material properties such as high specific strength, high corrosion resistance, high wear resistance and high anti-fatigue property. Due to these properties it is difficult to machine these alloys using conventional machining process. Nowadays non-conventional machining processes are widely used for machining such adavanced materials. Electrical Discharge machining (EDM) is one such non-conventional process, which can machine electrically conductive materials of any hardness values. Present study aims at drilling mesoscale 3 mm square holes on NiTi alloy by varying the electrical parameters namely, gap current, pulse on time and pulse off time. Additional, the present work includes finding out the effect of cryogenic treatment of NiTi work material on electrical discharge machining performance measures namely material removal rate (MRR) and tool wear rate (TWR). Based on experiments conducted, it can be concluded that with increase in current both material removal rate and tool wear rate increases. It is also noted that cryo-treatment of workpiece material improves MRR with respect to gap current. Similarly there is an increase in MRR with respect to pulse on time and pulse off time for cryo-treated workpiece material. There is a slight improvement of TWR with respect to gap current, pulse on time and pulse off time for cryo-treated workpiece material.

The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking

2014 ◽  
Vol 660 ◽  
pp. 43-47
Author(s):  
Amran Ali Mohd ◽  
Suraya Laily ◽  
Aisyah Fatin ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Aluminium Alloys ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the performance of brass electrode on the removal of aluminium alloys LM6 (Al-Sil2) in an electrical discharge machining (EDM) die-sinking. The machining parameters such as pulse-on time, pulse-off time and peak current were selected to find the responses on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Brass with diameter of 10mm was chosen as an electrode. Orthogonal array of Taguchi method was used to develop experimental matrix and to optimize the MRR, EWR and Ra. It is found that the current is the most significantly affected the MRR, EWR and Ra while pulse on time, pulse off time and voltage are less significant factor that affected the responses. Percentage optimum value of MRR increases to 3.99%, however EWR and Ra reduce to 3.10% and 2.48% respectively. Thus, it shows that brass having capability to cut aluminium alloys LM6.

scholarly journals Effect of Input Parameters on SR and MRR for Tool Steel AISI L2 By Electric Discharge Machine (EDM)

2021 ◽  
Vol 39 (6) ◽  
pp. 928-935
Author(s):  
Shukry H. Aghdeab ◽  
Raed R. Shwaish ◽  
Tahseen M. Salman
Keyword(s):  
Surface Roughness ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machine ◽  
Steel Aisi ◽  
Discharge Machine ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electric discharge machine (EDM) or may be call electric spark machine is one of the most important cutting process or manufacturing process because it gives high accurate dimension and can be produced the most complex shape. In this present material removal rate and surface roughness for tool steel AISI L2 studied. The input parametric for this process is current, pulse on time (Ton) and pulse off time (Toff).A full factorial method is used to formulate machine parameters and find the optimal process parameters of an electric spark. The result shows that the Surface roughness increasing with increasing current and pulse on time is increases while no effect by increase in pulse off time. Best surface roughness when using low current and pulse in time. The material removal rate is increasing with increasing in current and pulse on time while decreasing when pulse of time is increased. The experimented and predicted values by using Minilab17 software ​​of this process are approximately equal.

Optimization of Material Removal Rate in EDM Using Taguchi Method

2012 ◽  
Vol 626 ◽  
pp. 270-274 ◽  
Author(s):  
Milan Kumar Das ◽  
Kaushik Kumar ◽  
Tapan K. Barman ◽  
Prasanta Sahoo
Keyword(s):  
Material Removal Rate ◽  
Discharge Current ◽  
Orthogonal Array ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter ◽  
Off Time

This paper presents an investigation on the effect and optimization of machining parameters on material removal rate (MRR) in electrical discharge machining (EDM) of EN31 tool steel. For the experiment, four process parameters viz. pulse on time, pulse off time, discharge current and voltage are considered. The settings of machining parameters are determined by using Taguchis orthogonal array (OA). L27 orthogonal array (OA) is considered for the study. The level of importance of the machining parameters on MRR is determined by analysis of variance (ANOVA) test. The optimum machining parameter combination is obtained by the analysis of signal-to-noise (S/N) ratio. The analysis shows that discharge current has the most significant effect on MRR followed by pulse off time and voltage. It is seen that with an increase in discharge current and pulse off time, MRR increases in the studied range. The methodology described here is expected to be highly beneficial to manufacturing industries.

Optimasi Multirespon Purwarupa Electrical Discharge Machine (EDM) Menggunakan Metode Taguchi-Grey Relational Analysis

2019 ◽  
Vol 11 (01) ◽  
pp. 26-32
Author(s):  
Angga Sateria ◽  
Eko Yudo ◽  
Zulfitriyanto Zulfitriyanto
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
High Speed Steel ◽  
Machining Processes ◽  
Relational Analysis ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

EDM is one of the nonconventional machining processes when making workpieces with conventional machining processes is difficult. This process has been used effectively in machining hard, high-strength and high temperature materials such as high speed steel (HSS) materials. In this study, prototype of EDM machines was carried out with engine variables such as current (A), pulse on time (µs) and pulse off time (µs). The material used is high speed steel (HSS) material used in cutting tools such as turning tools and milling tools. Surface roughness and material removal rate are responses observed to determine the quality of material remaval. The quality characteristic of the surface roughness response is "smaller is better" and the quality characteristics of the material removal rate response is "larger is better. The purpose of this study is to determine the best process parameter level to achieve the required performance characteristics in the material removal process using prototype EDM machines using the gray relational analysis (GRA) method, three process parameters are selected such as current, pulse on time, and pulse off time. The taguchi 3 x 3 x 3 design is used as an experimental design.The best parameter level obtained is current 40 ampere, pulse on time 200 µs, pulse off time 20 µs.

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