scholarly journals Analysis of WEDM Process Parameters on Surface Roughness and Kerf using Taguchi Method

2017 ◽  
Vol 2 (4) ◽  
pp. 103-109 ◽  
Author(s):  
Asfana Banu ◽  
Mazilah Abu Bakar ◽  
Mohammad Yeakub Ali ◽  
Erry Y. T. Adesta
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Machining Parameters ◽  
Wire Tension ◽  
Wedm Process ◽  
Off Time

In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap. 

scholarly journals Modeling and experimental investigation of process parameters in WEDM for surface roughness using regression model

2018 ◽  
Vol 172 ◽  
pp. 04010
Author(s):  
A. Muniappan ◽  
R. Senthilkumar ◽  
V. Jayakumar ◽  
S. Venkata Ravikumar ◽  
P. Sai Tarunkumar
Keyword(s):  
Surface Roughness ◽  
Multiple Regression ◽  
Process Parameters ◽  
Wire Tension ◽  
Level 3 ◽  
Level 1 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time

The present study focused on the multiple regression modeling and predicting the surface roughness of the Aluminum hybrid composite during the WEDM process. The hybrid MMC was manufactured by process named as stir casting utilizing particulates of Silicon carbide and graphite each in Al6061 combination. The analyses were outlined with Taguchi L27 design matrix. Mathematical relationships between the surface roughness and WEDM cutting parameters (Pulse on time, Pulse off time, current, gap voltage, wire speed and wire tension) have been investigated. The results show that the multiple regression analysis is a successful method for developing a mathematical model to predict the surface roughness. The optimum value of process parameters for the predicted optimum value of surface roughness (1.285) is pulse on time 106 units (Level 1), pulse off time 60 units (Level 3), peak current 90 units (Level 2), gap set voltage 50 units (Level 3), wire speed3 units (Level 1) and wire tension 12 units (Level 3).The optimum results are adopted in validation study and the results based on WEDM process responses can be effectively improved.

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

scholarly journals Multi-Objective Optimization of Wire Electro Discharge Machining (WEDM) Process Parameters Using Grey-Fuzzy Approach

2018 ◽  
Vol 63 (1) ◽  
pp. 16-25 ◽  
Author(s):  
Partha Protim Das ◽  
Sunny Diyaley ◽  
Shankar Chakraborty ◽  
Ranjan Kumar Ghadai
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Machining Process ◽  
Wire Tension ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Fuzzy Logic Technique ◽  
Off Time

Wire electro discharge machining (WEDM) is a versatile non-traditional machining process that is extensively in use to machine the components having intricate profiles and shapes. In WEDM, it is very important to select the optimal process parameters so as to enhance the machine performance. This paper emphasizes the selection of optimal parametric combination of WEDM process while machining on EN31 steel, using grey-fuzzy logic technique. Process parameters such as servo voltage, wire tension, pulse-on-time and pulse-off-time were considered while taking into account several multi-responses such as material removal rate (MRR) and surface roughness (SR). It was found that pulse-on-time of 115 µs, pulse-off-time of 35 µs, servo voltage of 40 V and wire tension of 5 kgf results in a larger value of grey fuzzy reasoning grade (GFRG) which tends to maximize MRR and improve SR. Finally, analysis of variance (ANOVA) is applied to check the influence of each process parameters in the estimation of GFRG.

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.

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 Investigation of Process Parameters in Wire Electrical Discharge Machining by Response Surface Methodology on IS2062 Steel

2014 ◽  
Vol 550 ◽  
pp. 53-61
Author(s):  
R.Arun Bharathi ◽  
P.Ashoka Varthanan ◽  
K. Manoj Mathew
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Machining Parameters ◽  
Peak Current ◽  
Custom Design ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The objective of the present work is to predict the optimal set of process parameters such as peak current (IP), pulse on/off time (TON/TOFF) and spark gap voltage (SV) to achieve minimum Surface roughness (Ra), wire consumption rate (WCR) and maximum material removal rate (MRR). In this work, experiments were carried out by pulse arc discharges generated between ZnO coated brass wire and specimen (IS2062 steel) suspended in deionized water dielectric. The experiments were designed based on the above mentioned four factors, each having three levels. Custom design based Response Surface Methodology (RSM) is used in this research. 21 runs of experiments were constructed based on custom design procedure and results of the experimentation were analyzed analytically as well as graphically. Moreover the surface roughness after machining was measured by Taylor Hobson Surtronic device. Second order regression model has been developed for predicting Ra, WCR and MRR in terms of interactive and higher order machining parameters through RSM, utilizing relevant experimental data as obtained through experimentation. The research outcome identifies significant parametersand their effect on process performance on IS2062 steel. The results revealed that peak current, pulse on-time and their interactions have significant effects on Ra, whereas pulse off time and peak current have significant effects on MRR and it is also observed that peak current and interaction between peak current and pulse off time have significant effects on WCR. The adequacy of the above proposed models has been tested through the analysis of variance (ANOVA).

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%.

scholarly journals Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

2020 ◽  
Vol 12 (10) ◽  
pp. 168781402096758
Author(s):  
Tina Chaudhary ◽  
Arshad Noor Siddiquee ◽  
Arindam Kumar Chanda ◽  
Mustufa Haider Abidi ◽  
Abdulrahman Al-Ahmari
Keyword(s):  
Surface Roughness ◽  
Ethylene Glycol ◽  
Process Parameters ◽  
Dielectric Fluid ◽  
Alumina Powder ◽  
Response Factors ◽  
Machining Time ◽  
Wire Tension ◽  
Demineralized Water ◽  
Response Optimization

Generally, gear is an essential component in various electro-mechanical devices, but its manufacturing at the micro-level is challenging. The non-conventional manufacturing processes, such as electro-discharge machining (EDM), is suitable in gear fabrication. Although miniature gears have strict accuracy requirements, the optimization of the EDM process parameters, especially for advanced materials and alloys, is critical. In this paper, Nimonic alloy miniature gears are manufactured using wire-EDM and the effect of process parameters, such as peak current, pulse-off (POFF) time, pulse-on (PON) time, wire tension, and dielectric fluid on the response factors are analyzed. The primary response factors, such as surface roughness, machining time, material removal rate, kerf width (KW), surface microhardness, and depth of microhardness are considered. Also, different dielectric fluids are prepared, which include ethylene glycol mixed demineralized water, oxygen mixed demineralized water, ethylene glycol and alumina powder mixed demineralized water, and ethylene glycol alumina powder and oxygen mixed demineralized water. Furthermore, the effect of process parameters on the multi-response using Pareto ANOVA has been analyzed. The results demonstrate that ethylene glycol mixed demineralized water, as a dielectric fluid, is the most influencing parameter to reduce the surface roughness, machining time, KW, and improve micro-hardness. Thus, dielectric fluid is an essential factor obtained from multi-response optimization followed by peak current, POFF time, wire tension, and PON time.

Analysis of Effects of Machining Parameters on Surface Roughness in Electrical Discharge Machining Tablet Shape Punches Using Taguchi Method

2020 ◽  
Vol 977 ◽  
pp. 12-17
Author(s):  
Thi Hong Tran ◽  
Tien Dung Hoang ◽  
Hong Ky Le ◽  
Thi Tam Do ◽  
Thanh Hien Bui ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Copper Electrode ◽  
Machining Parameters ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper presents a study on analysis of influences of the surface roughness in Electrical Discharge Machining 90CrSi tablet shape punches with the use of copper electrode. In this paper, 9 experimental runs were designed and conducted by using Taguchi method. In addition, 4 process parameters including the gap voltage, the pulse current, the pulse on time and the pulse off time were investigated. The influences of these input parameters on the surface roughness were evaluated by analysing variance. Also, from the experimental results, optimum values of the input parameters for getting the minimum surface roughness were proposed.

scholarly journals Investigation and optimization of the electro-discharge machining parameters of 2024 aluminum alloy and Al/7.5% Al2O3 particulate-reinforced metal matrix composite

2018 ◽  
Vol 25 (1) ◽  
pp. 159-172 ◽  
Author(s):  
Saeed Daneshmand ◽  
Behnam Masoudi
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Matrix ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Tool Wear Rate ◽  
Electro Discharge Machining ◽  
Pulse Off Time ◽  
Off Time

AbstractBeing newly advanced materials, metal matrix composites enjoy the properties of high service temperature, light weight, high specific strength, good wear resistance, high stiffness, and a low thermal expansion coefficient. However, machining these materials by conventional methods is difficult. A key machining process for difficult-to-machine materials like composites is electro-discharge machining, which is widely used in non-conventional material removal processes. The current work aims to identify different parameters, such as voltage, current, pulse on-time, and pulse off-time, which influence the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). By applying regression equations, a mathematical model is adopted to estimate MRR, TWR, and SR. The optimum machining parameters are investigated using the Taguchi method with L9 orthogonal array. The optimum values are also analyzed by multi-objective Taguchi method with calculation of total normalized quality loss (TNQL) and multi-signal to noise ratio (MSNR) included. Analysis of the Taguchi method introduced voltage and pulse off-time as the two main significant factors that influence the value of the material removal rate. The discharge current and pulse off-time also have a statistically significant impact on both tool wear rate and surface roughness.

Sign in / Sign up

Export Citation Format

Share Document