scholarly journals A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Metals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 816
Author(s):  
Sarmad Ali Khan ◽  
Mudassar Rehman ◽  
Muhammad Umar Farooq ◽  
Muhammad Asad Ali ◽  
Rakhshanda Naveed ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Physical Science ◽  
Material Removal ◽  
Removal Rate ◽  
Recast Layer ◽  
Electric Discharge Machining ◽  
Recast Layer Thickness ◽  
Wire Electric Discharge Machining ◽  
Die And Mold ◽  
Wire Feed

Recently, DC53 die steel was introduced to the die and mold industry because of its excellent characteristics i.e., very good machinability and better engineering properties. DC53 demonstrates a strong capability to retain a near-net shape profile of the die, which is a very challenging process with materials. To produce complex and accurate die features, the use of the wire electric discharge machining (WEDM) process takes the lead in the manufacturing industry. However, the challenge is to understand the physical science of the process to improve surface features and service properties. In this study, a detailed yet systematic evaluation of process parameters investigation is made on the influence of a wire feed, pulse on duration, open voltage, and servo voltage on the productivity (material removal rate) and material quality (surface roughness, recast layer thickness, kerf width) against the requirements of mechanical-tooling industry. Based on parametric exploration, wire feed was found the most influential parameter on kerf width: KW (45.64%), pulse on time on surface roughness: SR (84.83%), open voltage on material removal rate: MRR (49.07%) and recast layer thickness: RLT (52.06%). Also, the optimized process parameters resulted in 1.710 µm SR, 10.367 mm3/min MRR, 0.327 mm KW, and 10.443 µm RLT. Moreover, the evolution of surface features and process complexities are thoroughly discussed based on the involved physical science. The recast layer, often considered as a process limitation, was explored with the aim of minimizing the layers’ depth, as well as the recast layer and heat-affected zone. The research provides regression models based on thorough investigation to support machinists for achieving required features.

Surfactant and graphite powder–assisted electrical discharge machining of titanium alloy

2016 ◽  
Vol 231 (4) ◽  
pp. 641-657 ◽  
Author(s):  
Murahari Kolli ◽  
Adepu Kumar
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Graphite Powder ◽  
Recast Layer ◽  
Dielectric Fluid ◽  
Recast Layer Thickness

Surfactant and graphite powder–assisted electrical discharge machining was proposed and experiments were performed on titanium alloy in this investigation. Analysis was carried out to observe changes in dielectric fluid behaviour, material removal rate, surface roughness, recast layer thickness, surface topography and energy-dispersive X-ray spectroscopy. It was found out that the addition of surfactant to dielectric fluid (electrical discharge machining oil + graphite powder) improved the material removal rate and surface roughness. It was noticed to have reduced the recast layer thickness and agglomeration of graphite and sediment particles. Biface material migrations between the electrode and the workpiece surface were identified, and migration behaviour was powerfully inhibited by the mixing of surfactant. Surfactant added into dielectric fluid played an important role in the discharge gap, which increased the conductivity, and suspended debris particles in dielectric fluid reduced the abnormal discharge conditions of the machine and improved the overall machining efficiency.

scholarly journals The Effect of Discharge Current and Pulse-On Time on Biocompatible Zr-based BMG Sinking-EDM

2020 ◽  
Vol 10 (1) ◽  
pp. 401-407
Author(s):  
Yanuar Rohmat Aji Pradana ◽  
Aldi Ferara ◽  
Aminnudin Aminnudin ◽  
Wahono Wahono ◽  
Jason Shian-Ching Jang
Keyword(s):  
Surface Roughness ◽  
Metallic Glasses ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Hardness ◽  
Recast Layer ◽  
Surface Evaporation ◽  
Pulse On Time

AbstractThe machinability information of Zr-based bulk metallic glasses (BMGs) are recently limited but essential to provide technological recommendation for the fabrication of the medical devices due to the material’s metastable nature. This study aims to investigate the material removal rate (MRR) and surface roughness under different current and pulse-on time of newly developed Ni- and Cu-free Zr-based BMG using sinking-electrical discharge machining (EDM). By using weightloss calculation, surface roughness test and scanning electron microscopy (SEM) observation on the workpiece after machining, both MRR and surface roughness were obtained to be increased up to 0.594 mm3/min and 5.50 μm, respectively, when the higher current was applied. On the other hand, the longer pulse-on time shifted the Ra into the higher value but lower the MRR value to only 0.183 mm3/min at 150 μs. Contrary, the surface hardness value was enhanced by both higher current and pulse-on time applied during machining indicating different level of structural change after high-temperature spark exposure on the BMG surface. These phenomena are strongly related to the surface evaporation which characterize the formation of crater and recast layer in various thicknesses and morphologies as well as the crystallization under the different discharge energy and exposure time.

scholarly journals Comparative Analysis of Machining Characteristics of EDM and ECM during Machining of Ti-6Al-4V

2021 ◽  
Vol 23 (2) ◽  
Author(s):  
Banwait S.S. ◽  
◽  
Sanjay S ◽  
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Pulse On Time ◽  
Surface Finish Effect ◽  
Machining Characteristics

The present work explains the machining of Titanium alloy using Electric Discharge Machining & Electro-Chemical Machining. This work aims to analyze the role of Current, Pulse on Time, Voltage and hence optimize the Material Removal Rate and Surface Roughness in Electric Discharge Machining. In the same way, it also aims to analyze the role of Concentration, Feed, and Voltage and optimize the Material Removal Rate and Surface Roughness in Electro-Chemical Machining. The various approaches like Taguchi & Analysis of Variance are executed to study the performance characteristics of the input parameters on the output parameters. The whole work is followed by a validation test and hence confirming the obtained values. Thus, it reveals the acceptability of the model. The work tells that Material Removal Rate and Surface Finish effect is more in Electro-Chemical Machining as compared to Electric Discharge Machining. For Material Removal Rate, Current and Feed are more responsible parameters for Electric Discharge Machining. In the same way; electrolyte concentration and Feed are more responsible parameters for Electro-Chemical Machining respectively.

Slant type taper profiling and prediction of profiling speed for a circular profile during in wire electric discharge machining using Hastelloy-X

2021 ◽  
pp. 095440622199239
Author(s):  
IV Manoj ◽  
S Narendranath
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Recast Layer ◽  
Electric Discharge Machining ◽  
Hastelloy X ◽  
Fuzzy Interference System ◽  
Interference System ◽  
Neuro Fuzzy ◽  
Circular Profile ◽  
Wire Electric Discharge Machining

Hastelloy-X a nickel-based alloy used in nozzles, flame holders, turbine blades, turbocharges, jet engine tailpipes, afterburner components etc. having complex tapering profiles. Wire electric discharge machining proves to be the most beneficial machining technique as it provides required accuracy for the components. In the present research, a slant type taper fixture is employed for achieving taper angles as convention tapering have many hindrances like wire bend, angular inaccuracy, guide wear, insufficient flushing and wire breakage etc. and machining a simple circular profile on Hastelloy-X. The behaviour of different output parameters like profiling speed, surface roughness, profile areas, microhardness and recast layer were investigated for various input parameters for machined taper components at 0°, 15° and 30°. The cutting speed override parameter influenced most on the profiling speed and surface roughness. The wire offset parameter was found to be the most significant factor in the case of circular profile areas that were machined. The variation of different output parameters to profiling/cutting speed and taper angle was also highlighted. It is found the recast layer decreased which indicated lesser thermal degradation at higher taper angles at different profiling parameters. This is also validated by the microhardness where the machined surface hardness of taper angular profiles was found to be greater than the 0° profiles. The artificial neural networks and adaptive neuro-fuzzy interference system were used for the prediction of profiling speed. The adaptive neuro-fuzzy interference system was found better in prediction as the percentage error varies between 0–5 per cent. In conclusion, the profiling speed influences both on the accuracy and surface of machined taper circular profiles.

scholarly journals Synthesis and Characterization of Mechanical Properties and Wire Cut EDM Process Parameters Analysis in AZ61 Magnesium Alloy + B4C + SiC

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3689
Author(s):  
Thanikodi Sathish ◽  
Vinayagam Mohanavel ◽  
Khalid Ansari ◽  
Rathinasamy Saravanan ◽  
Alagar Karthick ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Stir Casting ◽  
Electric Discharge Machining ◽  
Az61 Magnesium Alloy

Wire Cut Electric Discharge Machining (WCEDM) is a novel method for machining different materials with application of electrical energy by the movement of wire electrode. For this work, an AZ61 magnesium alloy with reinforcement of boron carbide and silicon carbide in different percentage levels was used and a plate was formed through stir casting technique. The process parameters of the stir casting process are namely reinforcement %, stirring speed, time of stirring, and process temperature. The specimens were removed from the casted AZ61 magnesium alloy composites through the Wire Cut Electric Discharge Machining (WCEDM) process, the material removal rate and surface roughness vales were carried out creatively. L 16 orthogonal array (OA) was used for this work to find the material removal rate (MRR) and surface roughness. The process parameters of WCEDM are pulse on time (105, 110, 115 and 120 µs), pulse off time (40, 50, 60 and 70 µs), wire feed rate (2, 4, 6 and 8 m/min), and current (3, 6, 9 and 12 Amps). Further, this study aimed to estimate the maximum ultimate tensile strength and micro hardness of the reinforced composites using the Taguchi route.

scholarly journals Effect of Machine Feed Rate on Kerf-Width, Material Removal Rate, and Surface Roughness in Machining of Al/SiC Composite Material with Wire Electrical Discharge Machine

2020 ◽  
Vol 70 (1) ◽  
pp. 81-88
Author(s):  
Manoj Modi ◽  
Gopal Agarwal ◽  
Swati D Chaugaonkar ◽  
Umesh Bhatia ◽  
Veerendra Patil
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Kerf Width ◽  
Discharge Machine ◽  
Wire Electric Discharge Machining ◽  
The Impact

AbstractThe impact of machine feed rates of Wire Electric Discharge Machining on the kerf-width (K-width), material-removal-rate (MR-R), and surface-roughness (S-R) in the machining of Al/SiC composite is practically analysed. The relation among the feed rates of machine and K-width, MR-R, S-R is graphically acquired. It is demonstrated that lesser rate of feed is responsible for generation of larger K-width, lesser MR-R, and good finish as compared to more feed rate.

Investigation on material removal rate, surface and subsurface characteristics in wire electro discharge machining of Ti50Ni50-xCux shape memory alloy

2015 ◽  
Vol 232 (2) ◽  
pp. 164-177 ◽  
Author(s):  
M Manjaiah ◽  
S Narendranath ◽  
S Basavarajappa ◽  
VN Gaitonde
Keyword(s):  
Shape Memory ◽  
Layer Thickness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Recast Layer ◽  
Phase Changes ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time

TiNiCu shape memory alloys have superior properties as compared with NITINOL due to their greater ductility, reduced hysteresis temperature range, and quick actuation response. The present article investigates the surface and subsurface modifications occurring due to wire electro discharge machining of Ti50Ni50-xCux shape memory alloy. The machining experiments were performed considering the pulse on time, pulse off time, and servo voltage as the process parameters. The influence of these parameters was studied on the material removal rate, surface roughness, recast layer thickness, microhardness, and phase changes in the machined surface. Longer pulse on time causes greater discharge energy, hence leading to higher material removal rate, surface roughness, and recast layer thickness. The machined surface hardness increased up to 900 Hv, which is about 59% increase with respect to the base material for longer pulse on time due to the recast layer thickness and the formation of oxides. A phase change on the machined surface was observed to cause the shape recoverability of the alloy. The microstructure, composition through EDAX, and the phase changes of the machined surface are also discussed in the article.

Sign in / Sign up

Export Citation Format

Share Document