scholarly journals Experimental investigation for the effects of wire EDM process parameters over the tapered cross-sectional workpieces of titanium alloys (Ti6Al-4V)

2020 ◽  
Vol 11 (1) ◽  
pp. 221-232
Author(s):  
Muhammad Wasif ◽  
Syed A. Iqbal ◽  
Anis Fatima ◽  
Saima Yaqoob ◽  
Muhammad Tufail
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Cross Sectional ◽  
Electro Discharge Machining ◽  
Controllable Factors ◽  
Roughness Analysis ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time ◽  
Response Variables

Abstract. The main purpose of this research is to examine the outcomes of process parameters of Wire Electro-discharge Machining over the tapered workpieces of Titanium Alloy (Ti6Al-4V). Taper angle, current and pulse-off time are considered as the controllable factors effecting the response variables. Each sample has been cut with varying sets of machine controllable parameters to assess their effect on response variables; kerf width, wire wear, Material Removal Rate and surface roughness. Analysis of variances is applied, and mean Reponses are determined to recognize and compare the most influencing parameters over the response variables for the WEDM Process. Regression model for the response variables are also developed using which optimized WEDM process parameters are determined for the optimal response variables. It can be concluded that varying thickness of materials due to tapered cross section affects all the four-response variable, while, current and pulse-off time along with their interactions have high impact over the response variables.

scholarly journals Multi-Objective Optimization of Wire Electro Discharge Machining (WEDM) Process Parameters Using Grey-Fuzzy Approach

2018 ◽  
Vol 63 (1) ◽  
pp. 16-25 ◽  
Author(s):  
Partha Protim Das ◽  
Sunny Diyaley ◽  
Shankar Chakraborty ◽  
Ranjan Kumar Ghadai
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Machining Process ◽  
Wire Tension ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Fuzzy Logic Technique ◽  
Off Time

Wire electro discharge machining (WEDM) is a versatile non-traditional machining process that is extensively in use to machine the components having intricate profiles and shapes. In WEDM, it is very important to select the optimal process parameters so as to enhance the machine performance. This paper emphasizes the selection of optimal parametric combination of WEDM process while machining on EN31 steel, using grey-fuzzy logic technique. Process parameters such as servo voltage, wire tension, pulse-on-time and pulse-off-time were considered while taking into account several multi-responses such as material removal rate (MRR) and surface roughness (SR). It was found that pulse-on-time of 115 µs, pulse-off-time of 35 µs, servo voltage of 40 V and wire tension of 5 kgf results in a larger value of grey fuzzy reasoning grade (GFRG) which tends to maximize MRR and improve SR. Finally, analysis of variance (ANOVA) is applied to check the influence of each process parameters in the estimation of GFRG.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

scholarly journals A Study On Machining Characteristics of Al7075-NiCr-Gr Metal Matrix Composites Through Wire – Cut Electro Discharge Machining

2021 ◽  
Author(s):  
R. Palani ◽  
M. Sakthivel ◽  
V. Chithambaram ◽  
Geetha Palani
Keyword(s):  
Removal Rate ◽  
Energy Dispersive Spectrometer ◽  
Stir Casting ◽  
Vital Role ◽  
Matrix Composites ◽  
Practical Applications ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Abstract The aluminium and its alloys play a vital role in industry for their wide practical applications. In the present work, Al7075 was reinforced with Ni-Cr and graphite by Stir casting method. Further the optimization of the machined composite was done by Taguchi method. It was inferred that the MRR value of 0.056435 g/min was obtained with input parameters of 8 amps current, 52 Volt, 4 µs pulse on time, 17 µs pulse off time by machining with WEDM and SR value of 3.3 µm showing smooth surface. The material removal rate of the composite was found and the morphology of the material was analysed by SEM with associated elemental analysis by energy dispersive spectrometer (EDS). The reinforcements present in the composite were also verified. The outcome of this micro structural investigation revealed that a non-uniform distribution of graphite particles takes place at all weight percentages of graphite reinforcement.

Optimization of WEDM process parameters in machining Nimonic 75 alloy using brass wire

2020 ◽  
Vol 16 (5) ◽  
pp. 1189-1202 ◽  
Author(s):  
Harvinder Singh ◽  
Vinod Kumar ◽  
Jathinder Kapoor
Keyword(s):  
Removal Efficiency ◽  
Process Parameters ◽  
Material Removal ◽  
Kerf Width ◽  
Content Type ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Nimonic 75 ◽  
Off Time

PurposeAn experimental study has been conducted to model and optimize wire electric discharge machining (WEDM) process parameters such as pulse-on time, pulse-off time, servo voltage and peak current for response characteristics during machining of Nimonic 75 alloy.Design/methodology/approachThe response surface methodology (RSM)-based Box–Behnken's design has been employed for experimental investigation. RSM is used for developing quadratic regression models for selected response variables i.e. material removal efficiency and kerf width. To validate the model, confirmation experiments have been performed. The multi-response optimization has been done using desirability function approach.FindingsThrough analysis of variation, the percent contribution of process parameters on the response characteristics has been found. Pulse-off time is the most significant parameter affecting the kerf width and material removal efficiency followed by pulse-on time. The quadratic regression models have been developed for prediction of selected response variables. An attempt has been made to optimize the WEDM parameters for material removal efficiency and kerf width. The recommended process parameter setting for maximum material removal efficiency and minimum kerf width have been found to be pulse-on time = 0.6 µs, pulse-off time = 14 µs, servo voltage = 25 V and peak current = 200 A.Originality/valueThe “kerf width” is an important response variable for maintaining dimensional accuracy of the machined component, but has not been given due attention by the researchers. In the present work, the developed regression model for “kerf width” can be used in estimating wire offset setting and thereby getting a dimensionally accurate product. The optimum process parameters obtained in WEDM of Nimonic 75 alloy will contribute in database of machining. The outcome of this study would be added to scare database of the machining of Nimonic 75 alloy and also would be extremely useful for making the technology charts for WEDM.

scholarly journals Taguchi Optimization In Machining Inconel 600 With WEDM Process Using Cryogenically Treated Brass Wire

2021 ◽  
Vol 309 ◽  
pp. 01110
Author(s):  
K. Satyanarayana ◽  
B Ramya Krishna ◽  
M. Bhargavi ◽  
R. Eswari Vasuki ◽  
K. Raj Kiran
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Inconel 600 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time ◽  
Brass Wire

Wire electric discharge machining (WEDM) is one amongst the unconventional machining processes which might cut all kinds of shapes with an accuracy of +/−0.001mm. It will cut the materials that conduct electricity and can even cut the exotic metals like tungsten carbide, Hastelloy, Inconel etc. In the present work, machining on Inconel 600 by wire EDM with cryogenically treated brass wire is performed. Brass wire of 0.25mm diameter has been cryogenically treated at −90°C, −100°C and −110°C temperatures separately. An Experimental layout is designed as per Taguchi’s L-9 orthogonal array and experiments were conducted by varying machining parameters viz. Voltage, Pulse ON time and Pulse OFF time. The machining parameters are optimized using Taguchi’s methodology for minimum surface roughness and maximum metal removal rate (MRR). A Mathematical regression model for surface roughness and MRR is generated with the help of regression analysis. Through the Analysis of Variance (ANOVA) It was found that for MRR, pulse on time is the foremost contributing factor with 32.69% and for surface roughness, pulse off time is the foremost contributing factor with 23.59%.

Nature-Inspired Metaheuristic Approach for Multi-Objective Optimization During WEDM Process

2018 ◽  
pp. 91-122
Author(s):  
Goutam Kumar Bose ◽  
Pritam Pain
Keyword(s):  
Removal Rate ◽  
Experimental Result ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
The Individual ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Grey Relation ◽  
Off Time

In this research paper Wire-Electric Discharge Machining (WEDM) is applied to machine AISI-D3 material in order to measure the performance of multi-objective responses like high material removal rate and low roughness. This contradictory objective is accomplished by the control parameters like Pulse on Time (Ton), Pulse off Time (Toff), Wire Feed (W/Feed) and Wire Tension (W/Ten) employing brass wire. Here the orthogonal array is used to developed 625 parametric combinations. The optimization of the contradictory responses is carried out in a metaheuristic environment. Artificial Neural Network is employed to train and validate the experimental result. Primarily the individual responses are optimized by employing Firefly algorithm (FA). This is followed by a multi-objective optimization through Genetic algorithm (GA) approach. As the results obtained through GA infer a domain of solutions, therefore Grey Relation Analysis (GRA) is applied where the weights are considered through Fuzzy set theory to ascertain the best parametric combination amongst the set of feasible alternatives.

Experimental Investigation and Optimization of Process Parameters Used in the Silicon Powder Mixed Electro Discharge Machining of Ti-6Al-4V Alloy Using Response Surface Methodology

2016 ◽  
Vol 16 (1) ◽  
pp. 21-32
Author(s):  
Nipun D. Gosai ◽  
Anand Y. Joshi
Keyword(s):  
Removal Rate ◽  
Silicon Powder ◽  
Machine Material ◽  
Electro Discharge Machining ◽  
Optimization Of Process Parameters ◽  
Set Up ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

AbstractTi-6Al-4V is extensively used as a piece of the avionics, auto, and biomedical fields; however is a difficult to machine material. Electro Discharge machining (EDM) is seen as one of the most ideal approaches to manage machining Ti-6Al-4V combination, since it is a noncontact electro-thermal machining method, and it is self-ruling from the mechanical properties of the readied material. In EDM, dielectric plays important role in machining operation. In present paper silicon powder suspended plus kerosene is used as dielectric to explore the effect of these dielectrics on the execution criteria such as material removal rate (MRR) and roughness (Ra) in the midst of machining of titanium combination (Ti-6Al-4V). Peak current, pulse on time, pulse off time and powder included into dielectric liquid of EDM were picked as methodology parameters to think about the PMEDM execution with respect to MRR and Ra. The examinations were finished in organizing mode on an exceptionally made exploratory set up developed in laboratory. The ideal qualities for execution parameter were found by performing analysis and suggested ideal conditions have been verified by conducting confirmation experiments.

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 Effect of Process Parameters on Machining Performances during Machining of Al7075-T6 in Electro-Discharge Machining

2019 ◽  
Vol 8 (4) ◽  
pp. 10100-10104
Keyword(s):  
Wear Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Wear Rate ◽  
Rotary Tool ◽  
Electro Discharge Machining ◽  
Spark Gap ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process

In the present study, the machining of Al7075-T6 has been carried out in Electro-discharge machining(EDM) process. Taguchi L9 orthogonal array is used to conduct the experiments with three levels of process parameters.The effect of process parameter like spark gap and pulse off time on the machining performances have been analyzed. The machining performances such as material removal rate (MRR) and tool wear rate (TWR) have been analyzed for both the stationary and rotary tool EDM. Moreover, surface morphology has been studied in both the machining environment. It has been found that MRR is more in the case of rotary tool EDM as compared to stationary tool EDM.

Identification of Optimal Process Parameters in Electro-Discharge Machining Using ANN and PSO

2018 ◽  
pp. 72-90 ◽  
Author(s):  
Kaushik Kumar ◽  
J. Paulo Davim
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Repair Work ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Time Pulse

Electrical Discharge Machining (EDM) process is a widely used machining process in several fabrication, construction and repair work applications. Considering Pulse-On Time, Pulse OFF time, Peak-Current and Gap voltage as the inputs and among all possible outputs, in the present work Material Removal Rate and Surface Roughness are considered as outputs. In order to reduce the number of experiments Design of Experiments (DOE) was undertaken using Orthogonal Array and later on the outputs were optimized using ANN and PSO. It was found that the results obtained from both the techniques were tallying with each other.

Sign in / Sign up

Export Citation Format

Share Document