scholarly journals Milling Microchannels in Monel 400 Alloy by Wire EDM: An Experimental Analysis

Micromachines ◽  
2020 ◽  
Vol 11 (5) ◽  
pp. 469 ◽  
Author(s):  
Mustafa Saleh ◽  
Saqib Anwar ◽  
Abdualziz El-Tamimi ◽  
Muneer Khan Mohammed ◽  
Shafiq Ahmad
Keyword(s):  
Surface Morphology ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Cross Sectional ◽  
Microhardness And Microstructure ◽  
Monel 400 ◽  
The One ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

This paper presents the results of an investigation on the capacity of wire electrical discharge machining (WEDM) to produce microchannels in the Nickel-based alloy, Monel 400. The main objective of the current study is to produce microchannels with desired/target geometry and acceptable surface quality. Square cross-sectional microchannels with dimensions of 500 × 500 µm were investigated. Experiments were conducted based on the one-factor-at-a-time approach for the key input WEDM process parameters, namely pulse-on time (TON), pulse-off time (TOFF), average gap voltage (VGAP), wire feed (WF), and dielectric flow rate (FR). Dimensional accuracy, machining speed, surface roughness, surface morphology, microhardness, and microstructure were analyzed to evaluate the microchannels. The minimum errors of 6% and 3% were observed in the width and depth of the microchannels, respectively. Furthermore, microchannels with enhanced surface integrity could be produced exhibiting smooth surface morphology and shallow recast layer (~0–2.55 µm).

A DoE–TOPSIS method-based meta-model for parametric optimization of non-traditional machining processes

2019 ◽  
Vol 14 (2) ◽  
pp. 430-455 ◽  
Author(s):  
Shankar Chakraborty ◽  
Prasenjit Chatterjee ◽  
Partha Protim Das
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Topsis Method ◽  
Machining Performance ◽  
Machining Processes ◽  
Inconel 718 Alloy ◽  
Content Type ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

PurposeTo meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries, non-traditional machining (NTM) processes have now become quite popular in manufacturing industries. To explore the fullest machining capability of these NTM processes, it is often required to operate them while setting their different controllable parameters at optimal levels. This paper aims to present a novel approach for selection of the optimal parametric mixes for different NTM processes in order to assist the concerned process engineers.Design/methodology/approachIn this paper, design of experiments (DoE) and technique for order preference by similarity to ideal solution (TOPSIS) are combined to develop the corresponding meta-models for identifying the optimal parametric combinations of two NTM processes, i.e. electrical discharge machining (EDM) and wire electrical discharge machining (WEDM) processes with respect to the computed TOPSIS scores.FindingsFor EDM operation on Inconel 718 alloy, lower settings of open circuit voltage and pulse-on time and higher settings of peak current, duty factor and flushing pressure will simultaneously optimize all the six responses. On the other hand, for the WEDM process, the best machining performance can be expected to occur at a parametric combination of zinc-coated wire, lower settings of pulse-on time, wire feed rate and sensitivity and intermediate setting of pulse-off time.Practical implicationsAs the development of these meta-models is based on the analysis of the experimental data, they are expected to be more practical, being immune to the introduction of additional parameters in the analysis. It is also observed that the derived optimal parametric settings would provide better values of the considered responses as compared to those already determined by past researchers.Originality/valueThis DoE–TOPSIS method-based approach can be applied to varieties of NTM as well as conventional machining processes to determine the optimal parametric combinations for having their improved machining performance.

An Investigation of the Influences of EDM Parameters and Tool Geometries on Radial Overcut for Monel 400 Material with Tungsten Copper Electrode

2015 ◽  
Vol 766-767 ◽  
pp. 908-913
Author(s):  
P. Padmini ◽  
S. Senthamilperarasu ◽  
B. Shanmuganathan ◽  
N.R.R. Anbusagar ◽  
P. Sengottuvel
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Dimensional Accuracy ◽  
Copper Electrode ◽  
Machining Process ◽  
Experimental Result ◽  
Machining Parameters ◽  
Radial Overcut ◽  
Monel 400 ◽  
Pulse On Time

Electrical-discharge Machining (EDM) is a nonconventional machining process utilizing an electric spark discharge from the electrode (-) towards the work piece (+) through the dielectric fluid. The Dimensional accuracy in this is very important consideration for the accuracy of the finished product. The objective of this experimental study is to determine parameters that offer the best dimensional accuracy in electrical discharge machining (EDM). Discharge current (A), Pulse On Time (Ton), Pulse Off Time (Toff ) and Circle,Rectangle,Triangle and Square Tool Geometrical Shapes (Geo) are taken as machining parameters. The experimental investigations are carried out on Monel 400 material using Tungsten copper electrode. The response of ROC is considered for improving the machining efficiency. Optimal combination of parameters was obtained Taguchi Optimization technique. The confirmation experiments results shows that the significant improvement in Radial Overcut was obtained. ANOVA have been used to analyze the contribution of individual parameters on ROC. The experimental result demonstrates that the Taguchi method satisfies the practical requirements

Multi-Objective Optimization of Wire Electrical Discharge Machining (WEDM) Process Parameters Using Weighted Sum Genetic Algorithm Approach

2016 ◽  
Vol 15 (02) ◽  
pp. 85-100 ◽  
Author(s):  
P. C. Padhi ◽  
S. S. Mahapatra ◽  
S. N. Yadav ◽  
D. K. Tripathy
Keyword(s):  
Genetic Algorithm ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Weighted Sum ◽  
Multi Objective ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter ◽  
Wedm Process

The present work is aimed at optimizing the cutting rate (CR), surface roughness (Ra) and dimensional deviation (DD) in wire electrical discharge machining (WEDM) of EN-31 steel considering various input parameters such as pulse-on-time, pulse-off-time, wire tension, spark gap set voltage and servo feed. A face centered central composite design of response surface methodology (RSM) has been adopted to develop the empirical model for the responses. It is often desired to obtain a single parameter setting that can decrease Ra and DD and increase CR simultaneously. Since the responses are conflicting in nature, it is difficult to obtain a single combination of cutting parameters satisfying all the objectives in any one solution. The optimum search of the machining parameter values for maximization of CR and minimization of Ra and DD are formulated as a multi-objective, multi-variable, nonlinear optimization problem using genetic algorithm weighted sum method to evaluate the performance.

scholarly journals Integration of Fuzzy AHP and Fuzzy TOPSIS Methods for Wire Electric Discharge Machining of Titanium (Ti6Al4V) Alloy Using RSM

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7408
Author(s):  
Kishan Fuse ◽  
Arrown Dalsaniya ◽  
Dhananj Modi ◽  
Jay Vora ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Fuzzy Ahp ◽  
Cutting Speed ◽  
High Hardness ◽  
Fuzzy Topsis ◽  
Ti6al4v Alloy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

Titanium and its alloys exhibit numerous uses in aerospace, automobile, biomedical and marine industries because of their enhanced mechanical properties. However, the machinability of titanium alloys can be cumbersome due to their lower density, high hardness, low thermal conductivity, and low elastic modulus. The wire electrical discharge machining (WEDM) process is an effective choice for machining titanium and its alloys due to its unique machining characteristics. The present work proposes multi-objective optimization of WEDM on Ti6Al4V alloy using a fuzzy integrated multi-criteria decision-making (MCDM) approach. The use of MCDM has become an active area of research due to its proven ability to solve complex problems. The novelty of the present work is to use integrated fuzzy analytic hierarchy process (AHP) and fuzzy technique for order preference by similarity to ideal situation (TOPSIS) to optimize the WEDM process. The experiments were systematically conducted adapting the face-centered central composite design approach of response surface methodology. Three independent factors—pulse-on time (Ton), pulse-off time (Toff), and current—were chosen, each having three levels to monitor the process response in terms of cutting speed (VC), material removal rate (MRR), and surface roughness (SR). To assess the relevance and significance of the models, an analysis of variance was carried out. The optimal process parameters after integrating fuzzy AHP coupled with fuzzy TOPSIS approach found were Ton = 40 µs, Toff = 15 µs, and current = 2A.

Optimization of Wire Electrical Discharge Machining Parameters of Activated Carbon Reinforced Aluminium Composite

2020 ◽  
Vol 979 ◽  
pp. 3-9
Author(s):  
G. Ramanan ◽  
M.Madhu Kiran Reddy ◽  
V. Manishankar
Keyword(s):  
Activated Carbon ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Influential Factors ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The quality of machining through process parameters on the responses in wire electrical discharge machining (WEDM) is studied. This paper discusses the optimization of parameters of a process in WEDM machining with the application of the desirability approach on the basis of response surface methodology (RSM). Pulse on time, servo speed rate, discharge current, and pulse off time have been considered as influential factors. The established experimental data of AA7075 aluminium reinforced with 9% of activated carbon composite to analyze the process parameter effects on responses, like material removal rate (MRR) and surface roughness (SR). After machining multiple regression analysis is used to find the interaction among the process parameters is obtained. The optimal parameters were found using the desirability optimization methodologies as 10.43mm3/min and 3.32μm respectively. The performance of the optimization test confirmed that the proposed method in this study effectively improves the performance of the WEDM process.

scholarly journals Experimental investigation of Wire Electrical Discharge Machining (WEDM) Process Parameters on SS304 using Taguchi method

2018 ◽  
Author(s):  
T Vijaya Babu ◽  
B Subbaratnam
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Taguchi’S Method ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

WEDM (Wire Electrical discharge machining) is a nonconventional machining processes used in complicated shapes with high accuracy which are not possible with other conventional methods .Stainless steel 304 is used in present experimental work. Experiments are completed using Taguchi’s method with L9 orthogonal array .The aim of this work is to optimize the WEDM process parameters by considering input parameters are pulse on time , pulse off time ,peak current and wire feed and experiments are conducted with help of input parameters at three levels and response output parameters are MRR (Material removal Rate) and Surface Roughness (SR).Setting of parameters using by Taguchi’s method.

Enhancing die corner accuracy using path modification strategy in wire electrical discharge machining of Monel 400

2016 ◽  
Vol 232 (2) ◽  
pp. 207-216 ◽  
Author(s):  
G Selvakumar ◽  
KG Thiruppathi Kuttalingam ◽  
M Selvaraj ◽  
J Manohar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Scanning Electron Micrographs ◽  
Controllable Factors ◽  
Monel 400 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Path Modification

In this study, path modification strategy is used to improve the accuracy of the die corner produced in wire electrical discharge machining process. Based on Taguchi’s L18 array, experiments are performed on Monel 400 alloy. The influence of the machine-controllable factors such as wire tension, open-circuit voltage, pulse-on time, pulse-off time and additional travel and uncontrollable factors namely corner angles and flushing nozzle height on the performance measures such as surface roughness, cutting speed, and corner error are studied. The outcome of this study reveals that the path modification value in terms of additional travel of 0.5 mm improves the corner accuracy of the profile by 35% as compared to the profile machined without adopting path modification strategy. The analyses of scanning electron micrographs are carried out. Finally, an optimal technological guideline is reported for ready industrial use.

scholarly journals Studying the Effect of Working Conditions on WEDM Machining Performance of Super Alloy Inconel 617

Machines ◽  
2020 ◽  
Vol 8 (3) ◽  
pp. 54
Author(s):  
Stefan Dzionk ◽  
Mieczysław S. Siemiątkowski
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Industrial Applications ◽  
Machining Performance ◽  
Inconel 617 ◽  
Flow Pressure ◽  
Research Experiment ◽  
Pulse Off Time ◽  
Wedm Process

Wire electrical discharge machining (WEDM) has been, for many years, a precise and efficient non-conventional manufacturing solution in various industrial applications, mostly involving the use of hard-to-machine materials like, among others, the Inconel super alloys. The focus of the present study is on exploring the effect of selected control parameters, including pulse duration, pulse-off time and the dielectric flow pressure on the WEDM process performance characteristics of Inconel 617 material, such as: volumetric material removal rate (MRR), the dimensional accuracy of cutting (reflected by the kerf width) and surface roughness (SR). The research experiment has been designed and carried out using the response surface methodology (RSM) accordingly with the Box–Behnken design scheme. The results of experiments derived in the form of a fitted regression model have been subjected to the analysis of variance (ANOVA) tests. Thus, the variable process parameters and the relevant interactions between them, characterized by a significant influence on the values of the derived output responses, could be explicitly determined.

scholarly journals Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 893 ◽  
Author(s):  
Katerina Mouralova ◽  
Libor Benes ◽  
Tomas Prokes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
...  
Keyword(s):  
Copper Alloy ◽  
Electrical Discharge Machining ◽  
Subsurface Layer ◽  
Cutting Speed ◽  
Response Monitoring ◽  
Composition Analysis ◽  
Cross Sectional ◽  
Optimal Setting ◽  
Pulse On Time ◽  
Pulse Off Time

The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out to optimize the machining of the copper alloy Ampcoloy 35, which is particularly useful in plastic injection moulds. Within the study, a half-factor experiment of 25-1 with 10 axial points and seven central points of a total of 33 rounds was carried out, which was focused on the response monitoring of the input factors in the form of the machine parameters setup: gap voltage, pulse on time, pulse off time, discharge current, and wire speed. Based on the study of the response in the form of cutting speed and surface topography, their statistical models were created, while the optimal setting of machine parameters was determined to maximize the cutting speed and minimize the topography parameters. Further, a detailed cross-sectional analysis of surface and subsurface layer morphology was performed using electron microscopy including chemical composition analysis. In order to study microstructural changes in the material at the atomic level, a lamella was created, which was then studied using a transmission electron microscope.

scholarly journals Multiple-Performance Optimization of Wire EDM Parameters for HDS H13 BY Using Taguchi Method

2021 ◽  
Vol 9 (12) ◽  
pp. 2291-2295
Author(s):  
Naveen Vats
Keyword(s):  
Taguchi Method ◽  
Performance Optimization ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Complex Shapes ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

Abstract: Wire electrical discharge machining is extensively used in machining of conductive materials. The WEDM process has the ability to machine complex shapes and hard electrically conductive metal components precisely. The main goal of wire electrical discharge machine manufacturers and users are to achieve a better stability and high productivity of the process with desired accuracy and minimum surface damage.The main objectives of the present research are to experimentally study the effect of various process parameters like pulse on time, pulse off time, wire feed, and wire tension on the performance measures like material removal rate, surface roughness and wire wear ratio. WEDM is a widely recognized unconventional material cutting process used to manufacture components with complex shapes and profiles of hard materials. In this paper we are presenting the development of WEDEM process using various pre define parameters using Taguchi method. Index Terms: WEDM, doe, orthogonal array, parameters, Taguchi method, H13, HDS, mean of means, SF, MRR, Ra, etc.

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