Experimental Investigation of Machining Parameters on Surface Roughness in Dry and Wet Wire-Electrical Discharge Machining

2011 ◽  
Vol 264-265 ◽  
pp. 831-836 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Zakaria Mohd Zain
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Local Heating ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Good Surface ◽  
Good Surface Finish ◽  
Wedm Process

Wire electrical discharge machining (WEDM) is a thermal process in which the workpiece and the wire (tool) experience an intense local heating in the discharge channel. The high power density results in the erosion of a part of the material from both electrodes by local melting and vaporization. Whilst good surface finish and high material removal rate of the workpiece is a major requirement, the effect of EDM machining factors on these requirements cannot be overlooked. This study investigate the effect of two different machining methods of dry and wet WEDM process as well as the effect of on-time and voltage on the surface roughness of the workpiece. The machining factors used for this study are the pulse current, on-time and voltage. The results of the effect of the two machining methods on the responses are investigated and reported in this paper.

An integrated evolutionary approach for modelling and optimization of wire electrical discharge machining

2011 ◽  
Vol 225 (4) ◽  
pp. 549-567
Author(s):  
D Kondayya ◽  
A Gopala Krishna
Keyword(s):  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Evolutionary Approach ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Machining Performance ◽  
Wedm Process ◽  
Modelling And Optimization

This paper presents an application of an integrated evolutionary approach for modelling and optimization of a wire electrical discharge machining (WEDM) process. The proposed methodology consists of two parts. In the first part, a novel application of genetic programming (GP) is proposed. GP is an evolutionary modelling algorithm which uses principles similar to genetic algorithms to model highly non-linear and complex processes, resulting in accurate and reliable models. Two important aspects of machining performance of WEDM, namely metal removal rate and surface roughness, are modelled based on experimental data using GP in terms of four prominent input variables. The effect of machining parameters on the performance measures is also reported. In the second part, as the chosen machining performances are opposite in nature, the problem under consideration is formulated as a multi-objective optimization problem and solved using an efficient evolutionary optimization algorithm, non-dominated sorting genetic algorithm-II (NSGA-II). The outcome of Pareto optimal solutions is presented. The work presents a fully fledged evolutionary approach for optimization of the process.

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.

Modeling and Optimization of Wire Electrical Discharge Machining of Cold-Work Steal 2601

2011 ◽  
Vol 383-390 ◽  
pp. 6695-6703 ◽  
Author(s):  
Abolfazl Golshan ◽  
Soheil Gohari ◽  
Ayob Amran
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Cold Work ◽  
Open Circuit ◽  
Experimental Result ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Input Parameters ◽  
Pulse Off Time

In this study, the appropriate input parameters for achieving minimum surface roughness and high material removal rate are selected for wire electrical discharge machining of cold-work steel 2601. Mathematical modeling acquired by experimental result analysis is used to find the relation between input parameters including electrical current, gap voltage, open-circuit voltage and pulse-off time and output parameters. Subsequently, with exploitation of variance analysis, importance and effective percentages of each parameter are studied. The combination of optimum machining parameters is acquired using the analysis of ratios of signal-to-noise. Finally, according to multiple-objective optimization, outputs acquired from Non-dominated Sorting Genetic Algorithm led in achieving appropriate models. The optimization results showed suggested method has a high performance in problem solving.

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.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

scholarly journals Optimasi Multirespon Proses Wire Electrical Discharge Machining untuk Pengerjaan Komponen Punch and Dies Bracket Konstruksi Kapal Alumunium

2019 ◽  
Vol 12 (2) ◽  
pp. 107
Author(s):  
Fipka Bisono ◽  
Dhika Aditya P.
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
White Layer ◽  
Performance Characteristics ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Process Variables ◽  
Relational Analysis ◽  
Wedm Process

Wire electrical discharge machining(WEDM) banyak digunakan untuk proses pembuatan punch and dies. Dimana material yang digunakan memiliki tingkat kekerasan yang sangat tinggi. Parameter pemesinan yang kurang tepat dapat menyebabkan hasil pemotongan yang tidak optimal. Penelitian ini dilakukan untuk mengoptimalkan beberapa karakteristik hasil proses pemesinan secara serentak dengan cara mevariasikan variabel-variabel proses pemesinan WEDM. Karakteristik hasil proses yang diteliti antara lain adalah lebar pemotongan, kekasaran permukaan, dan tebal lapisan white layer. Proses pemesinan dilakukan pada material tool steel SKD 11. Arc on time, on time, open voltage dan servo voltage merupakan variabel-variabel proses yang akan divariasikan. Rancangan percobaan dilakukan menggunakan metode Taguchi dengan matriks ortogonal L18(21x33) dengan dua kali replikasi. Sedangkan langkah yang digunakan untuk mengoptimasi karakteristik hasil proses pemesinan yang diteliti secara serentak adalah menggunakan metode grey relational analysis (GRA). Lebar pemotongan, kekasaran permukaan dan tebal lapisan white layer memiliki performance characteristics “smaller-is-better.” Hasil dari penelitian menunjukkan nilai variabel-variabel proses pemesinan yang menghasilkan kualitas karakteristik yang paling optimum adalah sebagai berikut: arc on time (1A), on time (4?s), open voltage (70V), dan servo voltage (40V). Dengan persentase kontribusi variabel proses dari yang terbesar berturut-turut adalah on time (65,09%), open voltage (11,35%), arc on time (7,71%), dan servo voltage (5,61%). Wire electrical discharge machining (WEDM) process is commonly used to make punch and dies. WEDM services are typically used to cut hard metals. Inappropriate machining parameters can cause suboptimal cutting results. This research was conducted to optimize several characteristics of the machining process simultaneously by varying WEDM machining process variables. Performance characteristics of the WEDM process include the kerf, surface roughness and thickness of the white layer. The machining process is carried out on SKD 11 tool steel material.  Arc on time, on time, open voltage and servo voltage are process variables that will be varied. The experimental matrix design was carried out using the Taguchi method L18 (21x33) orthogonal array with two replications. Then to optimize the performance characteristics of the machining process simultaneously is using the Gray Relational Analysis (GRA) method. Performance characteristics of kerf, surface roughness, and thickness of the white layer is "smaller-is-better". The results of the experiment indicate the value of the machining process variables that produce the most optimum quality performance characteristics are as follows: arc on time (1A), on time (4?s), open voltage (70V), and servo voltage (40V). And the percentage of contribution of the process variables from the largest to smallest are as follows: on time (65,09%), open voltage (11,35%), arc on time (7,71%), and servo voltage (5,61%).

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