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 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.

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.

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.

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.

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.

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.

Wire Electrical Discharge Machining – High Speed VS Abrasive Waterjet - A Case Study

2011 ◽  
Vol 189-193 ◽  
pp. 4245-4255
Author(s):  
Shi Jin Zhang ◽  
Yu Qiang Wu ◽  
Yan Li Wang
Keyword(s):  
Electrical Discharge ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Wire Electrical Discharge Machining ◽  
Technological Advancement ◽  
Proper Selection ◽  
Regular User

Technological advancement, on the one hand, made Electrical Discharge Machining (EDM) much faster. One example of that is the presence of Wire Electrical Discharge Machining – High Speed (WEDM-HS) machine, which makes the material removal rate as high as 80 . On the other hand, it also made Abrasive Waterjet (AWJ) achieve much better quality surface and tighter tolerance. As a result, these two types of machining process have converged to the point where they can complement one another quite nicely in selected applications. However, it does not mean user may pick any one for their applications. The proper selection not only decreases the manufacturing costs but also achieves better quality. This paper focuses on comparing WEDM-HS with AWJ by actually cutting a special designed sample. Through comparison from several aspects which include dimension precision, surface roughness, cost, cutting time and surface damage, a proper selection guidance for regular user has been provided.

Research on Electrical Discharge Machining for Injection Mold of Automotive Connector

2012 ◽  
Vol 522 ◽  
pp. 17-20
Author(s):  
Wei Min Pan ◽  
Ke Ke Shi ◽  
Xian Qing Lei
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Electrode ◽  
Injection Mold ◽  
Workpiece Material ◽  
Electrode Tool ◽  
Mating Surface ◽  
Plastic Components

Electrical discharge machining (EDM) processing is generally applied on the area of molding plastic component or mating surface required high accuracy. The areas determine the quality of the plastic components. The principle of EDM is based on the material vaporization of high potential difference across the workpiece and Tool electrode. Tool electrode and workpieces are discontiguous when the EDM processes. Because there is no mechanical contact, Hardness and strength of the workpiece material have minimal effect on the material removal rate .The application of EDM technology on injection mold of automotive connector is focused on in this paper. Processing of the complex cores is researched. The design and processing of the tool electrode have been completed in the meantime.

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