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.

scholarly journals Optimization of Process Parameters for Minimum Surface Roughness in Wire Electrical Discharge Machining of AISI 1045 Steel Using Taguchi Method

2021 ◽  
Vol 9 (10) ◽  
pp. 989-997
Author(s):  
Rouhan Rafiq
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time

Abstract: One of the important non-traditional machining processes is Wire Electrical Discharge Machining, used for machining difficult to machine materials like composites and inter-metallic materials. WEDM involves complex physical and chemical process including heating and cooling. Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact resistance are increasing. The WEDM satisfy the present demands of the manufacturing industries such as better finish, low tolerance, higher production rate, miniaturization etc. The consistent quality of parts being machined in WEDM is difficult because the process parameters cannot be controlled effectively. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researcher and practicing engineers for a very long time. The objective of the present study was to experimentally investigate the effects of various Wire Electrical Discharge Machining variables on Surface Roughness and Material Removal Rate of AISI 1045 using ANOVA method. Taguchi’s L18 Orthogonal Array was used to conduct experiments, which correspond to randomly chosen different combination of process parameters: wire type, pulse on time, pulse off time, peak current, servo voltage, wire feed rate, flushing pressure each to be varied in three different levels. The surface roughness and material removal rate were selected as output responses for the present investigation. The effect of all the input parameters on the output responses have been analyzed using analysis of variance (ANOVA). The effect of variation in input parameters has been studied on the output responses. Plots of S/N ratio have been used to determine the best relationship between the responses and the input parameters. In other words, the optimum set of input parameters for minimum surface roughness and maximum material removal rate were determined. It has been found that wire type, pulse on time are most significant factors for surface roughness and wire type, pulse on time, pulse off time, wire feed rate are most significant factors for material removal rate. Keywords: Input Parameters, Wire Electric Discharge Machining, ANOVA, Taguchi

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.

Soft Modeling of Wire Electrical Discharge Machining of WC-Co Composite

2011 ◽  
Vol 335-336 ◽  
pp. 535-540 ◽  
Author(s):  
Veluswamy Muthuraman ◽  
Raju Ramakrishnan
Keyword(s):  
Neural Networks ◽  
Surface Roughness ◽  
Artificial Neural Networks ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Ann Model

The prediction of optimal machining conditions for required surface roughness and material removal rate (MRR) plays a very significant role in process planning of wire electrical discharge machining (WEDM). Artificial neural networks (ANN) are widely applied to predict the performance characteristics of complex machining process like WEDM very accurately. This present work deals with the features of cutting operation by WEDM of tungsten carbide- cobalt composite(WC – Co) and an artificial neural networks(ANN) model in terms of machining parameters, developed to predict surface roughness(Ra) and material removal rate (MRR).The experiment was planned as per Taguchi’s L 27 orthogonal array. The predictive capacity of the models was validated. The test results indicate that the proposed models could adequately describe the performance indicators with the limits of the factors that are being investigated. Finally the accuracy of the developed ANN model was compared to the experimental values. It was observed that the proposed ANN model is good.

scholarly journals Integrated optimization model in wire electric discharge machining using Gaussian process regression and wolf pack algorithm approach while machining SiCp/Al composite

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401878740 ◽  
Author(s):  
Jun Ma ◽  
Wuyi Ming ◽  
Jinguang Du ◽  
Hao Huang ◽  
Wenbin He ◽  
...  
Keyword(s):  
Gaussian Process ◽  
Material Removal Rate ◽  
Optimization Model ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Gaussian Process Regression ◽  
Wire Electrical Discharge Machining ◽  
Al Composite

To further improve prediction accuracy and optimization quality of wire electrical discharge machining of SiCp/Al composite, trim cuts were performed using Taguchi experiment method to investigate the influence of cutting parameters, such as pulse duration ( Ton), pulse interval ( Toff), water pressure ( Wp), and wire tension ( Wt)), on material removal rate and three-dimensional surface characteristics ( Sq and Sa). An optimization model to predict material removal rate and surface quality was developed using a novel hybrid Gaussian process regression and wolf pack algorithm approach based on experiment results. Compared with linear regression model and back propagation neural network, the availability of Gaussian process regression is confirmed by experimental data. Results show that the worst average predictive error of five independent tests for material removal rate, Sq, and Sa are not more than 10.66%, 19.85%, and 22.4%, respectively. The proposed method in this article is an effective method to optimize the process parameters for guiding the actual wire electrical discharge machining process.

Sign in / Sign up

Export Citation Format

Share Document