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 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.

scholarly journals A Fuzzy Modelling for Selection of Machining Parameters in Wire Electrical Discharge Machining of D2 Steel

2020 ◽  
Vol 8 (5) ◽  
pp. 3045-3052
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Fuzzy Model ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Selection Of

Wire Electrical Discharge Machining (WEDM) is a widely used non-traditional machining process used for machining of hard and difficult-to-machine materials. Proper selection of machining parameters in WEDM is required for better output performance, such as Material Removal Rate (MRR), Wire Wear Rate (WWR) and Surface Roughness (SR) etc. In the present paper, Pulse ON time, Pulse OFF time, Peak Current, Spark Voltage, Wire Feed and Wire Tension were taken as the input parameters to optimize MRR, WWR and SR. A set of 27 experiments were performed as per Taguchi Design. A Fuzzy model has been proposed to select the optimum values of machining parameters. The proposed fuzzy model was found to predict the experimental values with more than 90 percent accuracy.

Mathematical Modeling of Machining Parameters in Electrical Discharge Machining with Cu-B4C Composite Electrode

2012 ◽  
Vol 488-489 ◽  
pp. 871-875
Author(s):  
V. Anandakrishnan ◽  
V. Senthilkumar
Keyword(s):  
Mathematical Models ◽  
Current Pulse ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Selection Of

Copper based metal matrix composite reinforced with Boron Carbide is a newly developed Electrical Discharge Machining (EDM) electrode showing better performance than the conventional copper based electrode. Right selection of machining parameters such as current, pulse on time and pulse off time is one of the most important aspects in EDM. In this paper an attempt has been made to develop mathematical models for relating the Material Removal Rate (MRR), Tool Removal Rate (TRR) and Surface roughness (Ra) to machining parameters (current, pulse-on time and pulse-off time). Furthermore, a study was carried out to analyze thSubscript texte effects of machining parameters on various performance parameters such as, MRR, TRR and Ra. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models, can adequately describe the performance within the limits of the factors being studied. Response surface modeling is used to develop surface and contour graphs to analyze the effects of EDM input parameters on outer parameters.

scholarly journals Multi-Objective Optimization of Wire Electrical Discharge Machining of AL 2124/SIC Composite

2019 ◽  
Vol 9 (1) ◽  
pp. 2155-2163
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Strength ◽  
Wire Electrical Discharge Machining ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Predicted Values ◽  
Pulse On Time ◽  
Pulse Off Time

The growing demand for the use of high strength to weight alloys in industries for manufacturing complex structures challenges the machinability of such advanced materials. In the present investigation, the machinability of SiC particle reinforced Al 2124 composite was studied on Wire electrical discharge machining (WEDM). The process parameters namely pulse on-time (Ton), pulse off time (Toff), peak current (IP), and servo voltage (SV) were optimized by utilizing the central composite design layout. The output responses such as kerf and material removal rate (MRR) were studied in detail. The single and multi-objective optimization was studied for a combination effect using Derringer’s desirability approach and Genetic Algorithm (GA). The experimental and predicted values for each response were validated at the optimized condition. The experimental results were found in line with the predicted values. Multi objective optimization of kerf and MRR by GA showing better result compared to RSM.

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.

scholarly journals Comparative Study on EDM of Ti-6Al-4V Using Circular and Convex Shaped Electrodes

2018 ◽  
Vol 7 (3.34) ◽  
pp. 256
Author(s):  
S Rajamanickam ◽  
R Palani ◽  
V Sathyamoorthy ◽  
Muppala Jagadeesh Varma ◽  
Shaik Shaik Mahammad Althaf ◽  
...  
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Copper Electrode ◽  
Machining Process ◽  
Project Work ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

As on today, Electrical Discharge Machining (EDM) is world famous unconventional machining process for electrically conductive materials. In this project work, Ti-6Al-4V is performed in electrical discharge machining using differently shaped (circular and convex) copper electrode. The machining parameters considered are the pulse on- time, pulse off-time, voltage and current to investigate machining characteristics like material removal rate and tool wear rate. Taguchi method is applied to frame experimental design. Ti-6Al-4V finds wide usage in industrial applications such as marine, aerospace, bio-medical and so on. 

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.

Analysis of wire erosion and workpiece surface roughness in wire electrical discharge machining

2003 ◽  
Vol 217 (5) ◽  
pp. 633-642 ◽  
Author(s):  
N Tosun ◽  
C Cogun
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Open Circuit ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Workpiece Surface ◽  
The Wire ◽  
Dielectric Flushing ◽  
Wire Wear

In this study, the effects of machining parameters on the wire wear, on the size of erosion craters on the wire and on the workpiece surface roughness were investigated experimentally in wire electrical discharge machining (WEDM). An attempt was made to correlate the crater volume and the pulse energy. The experiments were conducted under different settings of pulse duration, open-circuit voltage, wire speed and dielectric flushing pressure. The variations of the wire wear, the size of erosion craters on the wire and the workpiece surface roughness with machining parameters were modelled mathematically by using regression analysis. The relationship between the workpiece surface roughness and the crater size was established. The analysis of variance (ANOVA) and F-test were performed to obtain statistically significant process parameters and the percentage contribution of these parameters to the performance outputs.

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

Sign in / Sign up

Export Citation Format

Share Document