Experimental Study on Material Removal Capability with Vibration-Assisted WEDM

2015 ◽  
Vol 798 ◽  
pp. 362-366 ◽  
Author(s):  
P. Radhakrishnan ◽  
L. Vijayaraghavan ◽  
N. Ramesh Babu
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrode Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrode ◽  
Work Material ◽  
Aisi H13 ◽  
Wedm Process

Wire Electrical Discharge Machining (WEDM) is a thermal process that involves melting and vaporisation of work material by a wire electrode in order to obtain the required size. The present work covers a study to improve the material removal rate (MRR) and to machining required slot size by varying frequency lateral vibration of wire while WEDM machining on AISI H13. The machining experiments were conducted by means of two electrode wire materials such as brass and zinc coated wires. The experiments mainly focused on surface integrity aspects like surface/sub surface microstructure, kerf width and surface roughness modification of surfaces machined with Wire Electrical Discharge Machining. The experimental results present the machinability of work material with WEDM process with varying frequency of vibration of wire electrode materials.

Effect of cryogenic treated brass wire electrode on material removal rate in wire electrical discharge machining

2012 ◽  
Vol 226 (11) ◽  
pp. 2750-2758 ◽  
Author(s):  
Jatinder Kapoor ◽  
Sehijpal Singh ◽  
Jaimal Singh Khamba
Keyword(s):  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Cryogenic Treatment ◽  
Wire Electrical Discharge Machining ◽  
Wire Electrode ◽  
Deep Cryogenic Treatment ◽  
Brass Wire

In this article, the effect of cryogenic treatment on the brass wire electrode used in wire electrical discharge machining is investigated. Deep cryogenic (−184°C) treatment is given to the brass wire electrode. The microstructure and crystalline phase of deep and non-cryogenic treated brass wire electrodes is observed by scanning electron microscope and X-Ray diffraction. The experimental results show that the structure is more refined in deep cryogenic treatment as compared to non-cryogenic treatment. The electrical conductivity of deep electrode is greatly improved. The effect of deep cryogenic treatment on the brass wire electrode is also investigated for the performance of wire electrical discharge machining. Taguchi experimental design has been applied to investigate the optimal parameters for maximum material removal rate. The ANOVA analysis indicates that type of wire, pulse width, time between two pulses and wire tension are significant factors for maximization of material removal rate. The cryogenic treatment results in improved material removal rate.

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.

Cutting Characteristics of Titanium Graphite Composite by Wire Electrical Discharge Machining

2012 ◽  
Vol 630 ◽  
pp. 114-120 ◽  
Author(s):  
Mamidala Ramulu ◽  
Mathew Spaulding ◽  
P. Laxminarayana
Keyword(s):  
Composite Laminates ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Metal Composite ◽  
Workpiece Material ◽  
Graphite Composite ◽  
Wedm Process

To improve strength to weight ratios, the fiber reinforced polymer composite materials are often used in conjunction with another material, like metals, to form hybrid structure. This paper reports the feasibility of using wire electrical discharge machining (WEDM) for cutting Titanium/Graphite Hybrid Composites (TiGr). Slit and slot cuts with WEDM process has been performed. Cutting times and process parameters were recorded, and cut surface characteristics were evaluated both with an optical and scanning electron microscopy (SEM). The results in terms of cutting time, workpiece material removal rate, and damage were presented and discussed. It was found that use of WEDM is possible for machining advanced hybrid metal composite laminates with appropriate machine settings.

scholarly journals Wire electrical discharge machining nickel super alloy

Mechanik ◽  
2018 ◽  
Vol 91 (3) ◽  
pp. 220-222
Author(s):  
Rafał Świercz ◽  
Dorota Oniszczuk-Świercz ◽  
Rafał Nowicki
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Process Performance ◽  
Influence Of Process Parameters ◽  
Super Alloy ◽  
Quality Features

This article presents the influence of process parameters of wire electrical discharge machining using coated brass on the surface roughness and material removal rate of Inconel 718. Studies were conducted by design of the experiment. Based on the survey developed mathematical models which allow selecting the most favorable machining parameters depending on the desired process performance and quality features of the surface texture.

Performance characterization of powder mixed wire electrical discharge machining technique for processing of Ti6Al4V alloy

2021 ◽  
pp. 095440892110607
Author(s):  
Sadananda Chakraborty ◽  
Souren Mitra ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Ti6al4v Alloy ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Powder Concentration ◽  
Pulse Off Time ◽  
Off Time

Precision machining characteristics with high-dimensional accuracy make the material more adaptable towards the applications. The present study employs the powder mixed wire electrical discharge machining process to machine Ti6Al4V alloy material. In spite of limited drawbacks and enhanced output in the powder mixed wire electrical discharge machining process, the present problem has been formulated for improving the machining efficiency of Ti6Al4V. The impact of suspended powder characteristics on responses, that is, material removal rate and surface roughness, is examined throughout the process. The current investigation also focuses on the interaction effect of machining constraints along with Al2O3 abrasive mixed dielectric to achieve economical machining output for the Ti6Al4V material. An effort has been presented to obtain optimal solutions using the different methodologies, namely response surface methodology, grey relation analysis, and particle swarm optimization. The study reveals that discharge energy is deeply influenced by the peak current and pulse off time followed by powder concentration in the powder mixed wire electrical discharge machining process. The maximum material removal rate of 6.628 mm3/min and average surface finish of 1.386 μm are the outcome of the present study for a set of optimal machining settings, that is, pulse off time ( Toff) of 7.247 μs, pulse on time ( Ton) of 30 μs, peak current ( Ip) of 2 A, and powder concentration of 4 g/L. Finally, the proposed model has been verified that the hybrid particle swarm optimization technique has the highest adequate capability to achieve maximum output. Thus, the approach offered an enhancement on performance measures of Ti6Al4V alloy in the powder mixed wire electrical discharge machining process.

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