scholarly journals Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 1940 ◽  
Author(s):  
Kashif Ishfaq ◽  
Naveed Ahmad ◽  
Muhammad Jawad ◽  
Muhammad Asad Ali ◽  
Abdulrahman M. Al-Ahmari
Keyword(s):  
Stainless Steel ◽  
Thermal Resistance ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
High Surface ◽  
Cutting Speed ◽  
Industrial Applications ◽  
Simultaneous Optimization ◽  
Wire Electrical Discharge Machining ◽  
Ss 304

Stainless steel (SS 304) is commonly employed in industrial applications due to its considerable corrosion resistance, thermal resistance, and ductility. Most of its intended applications require the formation of complex profiles, which justify the use of wire electrical discharge machining (WEDM). However, its high thermal resistance imposes a limitation on acquiring adequate surface topography because of the high surface tension of the melt pool, which leads to the formation of spherical modules; ultimately, this compromises the surface quality. Furthermore, the stochastic nature of the process makes it difficult to optimize its performance, especially if more than one conflicting response is involved, such as high cutting speed with low surface roughness and kerf width. Therefore, this study aimed to comprehensively investigate the interaction of SS 304 and WEDM, with a prior focus on simultaneously optimizing all the conflicting responses using the Taguchi-based grey relational approach. Analysis of variance (ANOVA) revealed that the current was the most significant parameter for cutting speed and kerf, whereas roughness, voltage (45%), drum speed (25.8%), and nozzle offset distance (~21%) were major contributing factors. SEM micrographs showed that optimal settings not only ensured simultaneous optimization of the conflicting responses but also reduced the number and size of spherical modules.

Design and Tests of a Water-Cooling Micro-Channel Heat Sink Made by WEDM

2012 ◽  
Vol 459 ◽  
pp. 609-614
Author(s):  
Kuo Zoo Liang ◽  
A Cheng Wang ◽  
Chun Ho Liu ◽  
Lung Tasi ◽  
Yan Cherng Lin
Keyword(s):  
Thermal Resistance ◽  
Heat Sink ◽  
Electrical Discharge ◽  
Heat Dissipation ◽  
Electrical Discharge Machining ◽  
Input Power ◽  
Wire Electrical Discharge Machining ◽  
Micro Channel ◽  
Water Cooling ◽  
Computer Aided

The purpose of this research is to design a new heat sink of water-cooling. With the aid of CAE (computer aided engineering), WEDM (wire electrical discharge machining), and the concept of micro-channel design, a heat sink of water-cooling can then be built with the merit of a smaller volume and lower thermal resistance. From this paper, results of the experiment indicate that the thermal resistance of heat sink can be decreased to 0.12 °C/W with input power of 60W, flow rate of 0.6 LPM, and a better heat dissipation with the in input power of 100W or 140W can be revealed.

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 Performance evaluation of wire electrical discharge machining on Titanium Alloy

2018 ◽  
Vol 1 (1) ◽  
pp. 27-38
Author(s):  
Jun Qi Tan ◽  
Mohd Yazid Abu
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter

The experimental carried out to aim at the selection of the best condition machining parameter combination for wire electrical discharge machining (WEDM) of titanium alloy (Ti–6Al–4V). By using Design Expert 10 software, a series of experiments were performed by selecting pulse-on time, pulse-off time, servo voltage and peak current as parameters. The responses that considered were cutting speed, material removal rate, sparking gap and surface roughness. Based on ANOVA analysis, the effect from the parameters on the responses was determined. The optimum machining parameters setting for the maximum cutting speed, minimum sparking gap and minimum surface roughness were found by proceed optimization experiment. Then, each optimization response had their own combination setting on WEDM to cut titanium alloy. 3D response surface graph such as dome and bowl shape represent maximum and minimum point for the solutions had shown in the report. Finally, predicted and actual value from the experiment have been calculated for validation.

Experimental Study of Kerf Machined by Micro-WEDM

2009 ◽  
Vol 626-627 ◽  
pp. 261-266
Author(s):  
Shi Chun Di ◽  
Xu Yang Chu ◽  
Dong Bo Wei ◽  
Hong Zhang
Keyword(s):  
Experimental Study ◽  
Stainless Steel ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Machining Precision ◽  
Machining Speed ◽  
Micro Wedm

In Micro Wire Electrical Discharge Machining (Micro-WEDM), the kerf width varies with different machining parameters, which will greatly influence the machining precision. In order to study the kerf variations in Micro-WEDM, the influence of kerf variation is analyzed and the experiment considering the kerf width and machining speed are performed on self-developed micro-WEDM under different machining parameters. With the reference of the experiment results, 32μm wide slot is machined with Φ30μm wire-tool on stainless steel workpiece.

Sign in / Sign up

Export Citation Format

Share Document