scholarly journals Empirical Investigations during WEDM of Ni-27Cu-3.15Al-2Fe-1.5Mn Based Superalloy for High Temperature Corrosion Resistance Applications

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3470 ◽  
Author(s):  
Vivek Aggarwal ◽  
Catalin Iulian Pruncu ◽  
Jujhar Singh ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov
Keyword(s):  
Feed Rate ◽  
Research Work ◽  
Spark Gap ◽  
Nickel Copper ◽  
Cutting Rate ◽  
Response Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Monel K-500, a nickel–copper based alloy, is a very hard and tough material. Machining of such hard and tough materials always becomes a challenge for industry and this has been resolved by wire electric discharge machining (WEDM), a popular non-conventional machining method used for machining tough and hard materials having complex shapes. For the first time reported in this present research work is an experimental investigation executed on Ni-27Cu-3.15Al-2Fe-1.5Mn based superalloy using WEDM to model cutting rate (CR) and surface roughness (SR) using response surface methodology (RSM). The process parameters have been selected as pulse-on time, pulse-off time, spark-gap voltage and wire-feed rate. Experiments have been planned according to the central composite design (CCD). The results show that pulse-on time has a direct effect on CR while the pulse-off time has a reverse effect. The CR increases as pulse-on time increases, and decreases as pulse-off time increases. SR increases as pulse-on time increases, and decreases as pulse-off time increases. Furthermore, increase in spark-gap voltage decreases CR and SR both. The wire feed-rate has a negligible effect for both the response parameters. The optimized values of CR and SR achieved through multi-response optimization are 2.48 mm/min and 2.12 µm, respectively.

Multi-Feature Optimization of WEDM for Ti-6Al-4V by Applying a Hybrid Approach of Utility Theory Integrated With the Principal Component Analysis

2018 ◽  
Vol 5 (1) ◽  
pp. 32-51 ◽  
Author(s):  
Sachin Ashok Sonawane ◽  
M.L. Kulkarni
Keyword(s):  
Principal Component Analysis ◽  
Feed Rate ◽  
Utility Theory ◽  
Hybrid Approach ◽  
Principal Component ◽  
Feature Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

In this study, multi-feature optimization is performed using a hybrid approach of utility theory (UT) combined with the principal component analysis (PCA) during wire electrical discharge machining (WEDM) of Ti-6Al-4V. Taguchi's L27 orthogonal collection is used to evaluate the effects of the pulse on time, pulse off time, peak current, servo voltage, wire feed rate and cable tension on surface roughness (SR), overcut and metal removal rate (MRR). The utility concept is employed to turn the multi-feature problem into a distinct equivalent feature called as overall efficiency index (OEI). Optimal sets of governing parameters using a hybrid approach are established as the pulse on time 114 machine unit, pulse off time 55 machine unit, servo voltage 20 volts, peak current 190 Amp., wire feed rate 5 m/min and cable tension 2 device unit. Scanning Electron Microscopic (SEM) analysis of cut surfaces shows a lump of debris, microvoids, micro-cracks, and large dark craters at high values of the pulse on time.

scholarly journals Analysis of Machining Parameters in WEDM of Al/SiCp20 MMC Using Taguchi-Based Grey-Fuzzy Approach

2019 ◽  
Vol 2019 ◽  
pp. 1-13 ◽  
Author(s):  
Mangesh R. Phate ◽  
Shraddha B. Toney ◽  
Vikas R. Phate
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Machining Parameters ◽  
Peak Current ◽  
Experimental Findings ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Aluminium silicate metal matrix composite (AlSiC MMC) is satisfying the requirement of material with good mechanical, thermal properties, and good wear resistance. But the difficulties during the machining are the main hurdles to its replacement for other materials. Wire electric discharge machining (WEDM) is a very effective process used for this type of difficult-to-cut material. So an effort has been taken to find out the most favourable level of input parameters for WEDM of AlSiC (20%) composite using a Taguchi-based hybrid grey-fuzzy grade (GFG) approach. The plan for experimentation is designed using Taguchi’s L9 (23) array. The various process parameters considered for the investigation are pulse on time (TON), pulse off time (TOFF), wire feed rate (WFR), and peak current (IP). Surface integrity such as surface roughness measured during the different types of cutting (along straight, inclined, and curvature directions) is considered in the present work. Grey relational analysis (GRA) pooled with the fuzzy logic is effectively used to find out the grey-fuzzy reasoning grade (GFRG). The Taguchi approach is coupled with the GFRG to obtain the optimum set of process parameters. From the experimental findings, it has been observed that the most economical process parameters for WEDM of AlSiCp20 were the pulse on time is 108 microsec, pulse off time is 56 microsec, wire feed rate (WFR) is 4 m/min, and peak current (IP) is 11 amp. From the analysis of variance (ANOVA), it is observed that the pulse on time is the foremost influencing parameters that contribute towards GFRG by 52.61%, followed by the wire feed rate (WFR) 38.32% and the current by 5.45%.

Multi-objective optimization of WEDM process parameters of Ti49.4-Ni50.6 shape memory alloy for orthopaedic implant application

2018 ◽  
Vol 1 (93) ◽  
pp. 12-31
Author(s):  
A.M. Takale ◽  
N.K. Chougule
Keyword(s):  
Shape Memory Alloy ◽  
Shape Memory ◽  
Process Parameters ◽  
Orthopaedic Implant ◽  
Wire Tension ◽  
Spark Gap ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Purpose: This paper focuses on the investigation on the effect of process parameters such as pulse on time (Ton), pulse off time (Toff), spark gap set voltage (SV), wire feed (WF) and wire tension (WT) on the responses such as the material removal rate (MRR), surface roughness (SR), kerf width (KW) and dimensional deviations (DD) of Ti49.4Ni50.6 (at.%) shape memory alloy (SMA) machined by WEDM. Ti-Ni SMA has fascinating properties and biocompatibility, it is considered for the present work. Design/methodology/approach: As per the Taguchi technique, L18 orthogonal array experiments on WEDM have been performed. The signals to noise (S/N) ratio plots are analysed to determine the influence of process parameters. Analysis has been tested through analysis of variance (ANOVA). SEM images are taken to confirm the results offering better surface quality. Findings: It was observed that pulse on time is the most significant factor for MRR and SR with the contribution of 35.69% and 59.02% respectively. The SV is a significant factor for KW and DD with contributions of 47.35% and 30.03% at 95% confidence level. A multi-response optimization has been carried out using grey relational analysis (GRA) to determine the optimum combination of process parameters. It is shown that, through GRA the optimal machining parameter setting such as A2B1C3D2E1 i.e. (pulse on time of 115 machine unit, pulse off time of 20 machine unit, spark gap set voltage of 90 V, wire feed of 6 m/min and wire tension of 3 machine unit) has been observed for maximum MRR and minimum SR, KW and DD. Young’s modulus checked for biocompatibility. Research limitations/implications: Heat treatment process like annealing is found to be most suitable to recover shape memory effect of WEDMed samples.

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.

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 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.

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.

scholarly journals Experimental Research of Wire Cut EDM for SR & MRR using Taguchi Method

2019 ◽  
Vol 9 (2) ◽  
pp. 3096-3099
Keyword(s):  
Taguchi Method ◽  
Experimental Research ◽  
Research Work ◽  
Work Piece ◽  
Factors Affecting ◽  
Pulse Peak ◽  
Nickel Composites ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The present research work is to examine & advance the latent procedure factors affecting the MRR, SR and Electrode Attire despite the fact machining of Nickel composites utilizing WEDM progression. This exertion includes investigation of the connection amid the different information route considerations like Pulse-on time(Ton), Pulse off time(Toff), Pulse Peak Current(IP), Wire substantial, Work piece material & procedure factors. In light of the picked information parameters and execution estimates L-16 symmetrical exhibit is chosen to streamline the most appropriate qualities for machining for nickel amalgams by WEDM…

scholarly journals Parametric Study of Machining on EN31 and EN19 Alloy Steels in WEDM to Analyze the Effect on Surface Roughness

2018 ◽  
Vol 7 (2) ◽  
pp. 36-42
Author(s):  
Ramandeep Singh ◽  
Ashok Kumar
Keyword(s):  
Surface Roughness ◽  
Input Parameter ◽  
Hard Materials ◽  
Current Voltage ◽  
Alloy Steels ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

Wire EDM can machine hard materials as well as alloys. Thus this study aims to analyze the effect of process parameters in WEDM on EN31 and EN19 alloy steels. The parameters selected for the optimization were Work material, Pulse on Time, Pulse off Time, Current, Voltage and Wire Feed for improvement in surface roughness. Taguchi L18 Orthogonal array was used for the best combination of experiment. The output responses were analyzed by ANOVA (Analysis of variance). The ANOVA result indicated that there is a significant effect on improvement in surface roughness when machining with all these six input parameter and coated wire. According to the present investigation, voltage was found to be the most significant factor followed by Ton and current, which affect the improvement in surface roughness.

scholarly journals Utility approach for multi target streamlining of process parameters in wire EDM

2018 ◽  
Vol 172 ◽  
pp. 04006
Author(s):  
A. Muniappan ◽  
M. Ajithkumar ◽  
V. Jayakumar ◽  
C. Thiagarajan ◽  
M. Sreenivasulu
Keyword(s):  
Machining Parameters ◽  
Wire Edm ◽  
Time Duration ◽  
Level 3 ◽  
Level 1 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Utility Approach ◽  
Wire Feed

This paper depicts the improvement of multireaction enhancement system utilizing utility technique to foresee and select the ideal setting of machining parameters in wire electro-release machining (WEDM) process. Investigations were arranged utilizing Taguchi's L27 orthogonal exhibit. A wide range of Wire EDM control variables such as pulse on time duration, pulse off time duration, servo voltage along with wire feed rate were judged for investigation. Multi reaction enhancement was performed for both cutting pace (CS) and surface unpleasantness (SR) utilizing utility idea to discover the ideal procedure parameter setting. The level of essentialness of the machining parameters for their impact on the CS and SR were controlled by utilizing investigation of fluctuation (ANOVA). In present study utility approach method used to optimize the process parameter in wire EDM of magnesium Al6061/SiC/Graphite hybrid composite with zinc covered brass wire electrode. The approach depicted here is relied upon to be profoundly useful to assembling enterprises, and furthermore different territories, for example, aviation, car and apparatus making businesses. The parameters corresponding to experiment run number 7 are pulse on time 108 units (Level 1), pulse off time 60 units (Level 3), peak current 230 units (Level 3), gap set voltage 60 units (Level 3), wire feed 3 units (Level 1) and wire tension 4 units (Level 1) are the best combination to achieve better surface roughness and cutting speed.

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