Multi-response Optimization in Wire Electrical Discharge Machining (WEDM) of Al6061/SiCp Composite Using Hybrid Approach

2015 ◽  
Vol 15 (4) ◽  
pp. 327-338 ◽  
Author(s):  
K. Anand Babu ◽  
P. Venkataramaiah
Keyword(s):  
Silicon Carbide ◽  
Process Parameters ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

AbstractIn recent days, the silicon carbide particulate reinforced aluminium metal matrix composites are most promising material in various engineering applications due to their strength to weight ratio, wear resistance and thermal resistance over the non-reinforced alloys. However, these materials are very difficult to cut by conventional machining methods due to the presence of silicon carbide particles. To overcome this limitation, the wire electrical discharge machining (WEDM) is employed to machine these composites. The aim of this study is to optimize the process parameters in wire electrical discharge machining (WEDM) of Al6061/SiCp composite using AHP-TOPSIS method. Al 6061/2% SiCp/3 µm particulate metal matrix composite is fabricated by using stir casting method and the uniformity of particle distribution was analyzed by SEM. Taguchi L18 orthogonal array is designed by considering various process parameters viz. Wire Type (WT), Pulse ON Time (T ON), Pulse OFF Time (T OFF), Wire Feed rate (WF) and Sensitivity (S) for conducting WEDM experiments. The obtained experimental results were analyzed and the results revealed that Sensitivity (S) is the prevailing factor on the response characteristics of WEDM followed by pulse ON time (T ON), wire feed rate (WF), Wire Type (WT) and pulse OFF time (T OFF).

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

Experimental Evaluation on Corner Accuracy in WEDM for Aluminium 6061 Alloy

2021 ◽  
pp. 96-113
Author(s):  
Debal Pramanik ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Thermal Process ◽  
Electrical Discharge Machining ◽  
Sharp Corner ◽  
Proposed Model ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

An important electro-thermal process known as wire electrical discharge machining (WEDM) is applied for machining of conductive materials to generate most precisely. All cutting inaccuracies of WEDM arise out of the major cause of wire bending. At the time of cutting a sharp corner or cut profile, bending of the wire leads to a geometrical error on the workpiece. Though this type of error may be of a few hundred microns, it is not suitable for micro applications. In this research study, an experimental investigation based on response surface methodology (RSM) has been done on wire EDM of Aluminium 6061 t6 alloy. This chapter studies the outcome of input process variables (i.e., wire feed rate, pulse on time, pulse off time, and gap voltage) on machining output responses (i.e., corner inaccuracy) extensively. Experimental validation of the proposed model shows that corner inaccuracy value may be reduced by modification of input parameters.

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

Parameter optimization and experimental study on wire electrical discharge machining of porous Ni40Ti60 alloy

2015 ◽  
Vol 231 (6) ◽  
pp. 956-970 ◽  
Author(s):  
Neeraj Sharma ◽  
Tilak Raj ◽  
Kamal Kumar Jangra
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Influence Of Process Parameters ◽  
Work Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Response Variables

NiTi is a shape memory alloy, mostly employed in cardiovascular stents, orthopedic implants, orthodontic wires, micro-electromechanical systems and so on. The effective and net shape machining of NiTi is very critical for excellent response of this material in medical and other applications. The present experimental work on wire electrical discharge machining process identifies the influence of process parameters that affect the cutting rate, dimensional shift and surface roughness while machining of porous nickel–titanium (Ni40Ti60) alloy. Porous Ni40Ti60 alloy was produced in-house using powder metallurgy technique. Response surface methodology–based central composite rotatable design has been used for the planning of experiments on wire electrical discharge machining. Empirical relations have been developed between the process parameters (pulse on-time, pulse off-time, servo voltage and peak current) and response variables. Desirability approach has been used for optimizing the three response variables simultaneously. Confirmation experiments were also performed at the optimized settings and reflect a close agreement between the predicted and experimental values (percentage error varies from −6.13% to +6.85%). Using wire electrical discharge machining, NiTi alloy can be machined easily and successfully in single-cutting operation, but after the first cut in wire electrical discharge machining, a surface projection appears on work surface which is the unmachined material on work surface.

scholarly journals Parametric Study for Wire Cut Electrical Discharge Machining of Sintered Titanium

2019 ◽  
Vol 69 (1) ◽  
pp. 17-38 ◽  
Author(s):  
De Dwaipayan ◽  
Nandi Titas ◽  
Bandyopadhyay Asish
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Sintered Titanium ◽  
Wire Tension ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

AbstractIn 21st century, it has been observed that Wire Cut Electrical Discharge Machining (WEDM) has evolved as one of the most important non-traditional machining process. The popularity and its success lies because of its uniqueness towards producing different components which are very difficult to machine like titanium, tungsten carbide, Inconel materials etc and provides a platform in producing intricate complex shape which in many cases become impossible to machine by traditional machining methods. Pure sintered titanium bears very high specific strength, abrasion and corrosion resistances and thus machining this type of materials by conventional techniques becomes very difficult though this material finds immense applications in bio-plant and aerospace components. In the present work, WEDM on pure sintered titanium is studied. The different input parameters of WEDM like, pulse on time, pulse off time, wire tension and wire feed have been varied to investigate the output response like MRR, Surface Roughness (Ra), Kerf Width and Over Cut. A response surface methodology (4 factors 3 level) design of experiment (DOE) has been applied in this context to examine the machining ability of pure sintered titanium and results are found to be satisfactory and verified by confirmatory test. The machining parameters like pulse on time, pulse off time, wire tension and wire feed shows immense effect on the output responses and present study provide an optimal conditions of these input parameters to get the best output responses through RSM

Optimization of Wire Electrical Discharge Machining Parameters of Activated Carbon Reinforced Aluminium Composite

2020 ◽  
Vol 979 ◽  
pp. 3-9
Author(s):  
G. Ramanan ◽  
M.Madhu Kiran Reddy ◽  
V. Manishankar
Keyword(s):  
Activated Carbon ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Influential Factors ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The quality of machining through process parameters on the responses in wire electrical discharge machining (WEDM) is studied. This paper discusses the optimization of parameters of a process in WEDM machining with the application of the desirability approach on the basis of response surface methodology (RSM). Pulse on time, servo speed rate, discharge current, and pulse off time have been considered as influential factors. The established experimental data of AA7075 aluminium reinforced with 9% of activated carbon composite to analyze the process parameter effects on responses, like material removal rate (MRR) and surface roughness (SR). After machining multiple regression analysis is used to find the interaction among the process parameters is obtained. The optimal parameters were found using the desirability optimization methodologies as 10.43mm3/min and 3.32μm respectively. The performance of the optimization test confirmed that the proposed method in this study effectively improves the performance of the WEDM process.

Machining of B1914 nickel-based superalloy using wire electrical discharge machining

2021 ◽  
pp. 095440892110317
Author(s):  
Katerina Mouralova ◽  
Ales Polzer ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
...  
Keyword(s):  
Surface Topography ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Wire Electrical Discharge Machining ◽  
Nickel Based Superalloy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The unconventional technology of wire electrical discharge machining is a key engineering technology, designed primarily for machining of conventionally difficult machine materials. One of them is nickel alloys, which are majorly used in the aerospace and energy industries. The subject of research in this study was specifically the B1914 nickel-based superalloy, which was subjected to many analyses leading to an overall optimization of its machining using wire electrical discharge machining. In order to determine the effect of machine parameters setup (pulse off time, gap voltage, discharge current, pulse on time and wire feed) on cutting speed, topography, morphology, surface and subsurface layer quality, an extensive Box–Behnken design experiment consisting of 46 rounds was carried out. The analyses of the condition of the surface and subsurface layers were performed, including their chemical composition and changes caused by wire electrical discharge machining. It was found out that the factors like pulse off time, discharge current and pulse on time have the greatest effect on the cutting speed, although from the point of view of surface topography the parameter pulse off time is not significant. The remaining two parameters cause the cutting speed to act against the surface topography i.e. with the increasing cutting speed, the surface topography gets worse and vice versa.

scholarly journals Experimental investigation of Wire Electrical Discharge Machining (WEDM) Process Parameters on SS304 using Taguchi method

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.

scholarly journals Parametric Optimization of EDM Process for Hybrid Metal Matrix using GRA Method

2019 ◽  
Vol 8 (3) ◽  
pp. 5844-5848
Keyword(s):  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Matrix Composites ◽  
Hybrid Metal Matrix Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Grey Relation ◽  
Off Time ◽  
Edm Process

Metal matrix composites (MMC’s) have evolved an extreme attention in current era for their superior applications in aerospace, defence and automobile industries. Metal matrix composites are found as current materials, possessing the characteristics of light in weight, greater wear resistance & superior specific strength. Due to presents of high hardened reinforcement strength, composite materials are very difficult to do machining by traditional techniques. Therefore unconventional machining like Electrical Discharge Machining becomes feasible method to these kinds of composite materials. EDM process does not require any mechanical energy because there is no direct contact between tool and workpiece. So there no influence of superior material properties like hardness, strength, toughness etc in machining hybrid metal matrix composite. In the present paper , an analysis is carried out to evaluate the influence of input parameters such as peak current (I), tool lift (TL), pulse off time (T off) and pulse on time (Ton) on the machining of 90%-Al(6061)-3 weight % silicon carbide (SiC)-7 weight % boron carbide (B4C) hybrid metal matrix composite through electrical discharge machining. The individual parameters were analyzed with an objective to minimize tool wear ratio (TWR) and to maximize the material removal rate (MRR). The grey relation grade (GRG) for Electric discharge machining is obtained by using taghuchi based grey relation analysis (GRA) method with multiple response parameters like MRR and TWR. The ANOVA based GRA method is employed to find the significance of process parameters like Peak Current, Pulse on time, and Pulse off time and Tool lif

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

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