scholarly journals Comparison of optimization techniques for MRR and surface roughness in wire EDM process for gear cutting

2017 ◽  
pp. 251-262 ◽  
Author(s):  
K.D. Mohapatra ◽  
M.P. Satpathy ◽  
S.K. Sahoo
Keyword(s):  
Surface Roughness ◽  
Optimization Techniques ◽  
Wire Edm ◽  
Gear Cutting ◽  
Edm Process

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

Optimization of Surface Roughness Parameters by Different Multi-Response Optimization Techniques During Electro-Discharge Machining of Titanium Alloy

2019 ◽  
pp. 82-108 ◽  
Author(s):  
Anshuman Kumar Sahu ◽  
Siba Sankar Mahapatra
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Discharge Current ◽  
Desirability Function ◽  
Optimization Techniques ◽  
Work Piece ◽  
Tool Electrode ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Edm Process

In this chapter, the EDM process is performed by taking titanium alloy as work piece and AlSiMg prepared by selective laser sintering (SLS) process as tool electrode along with copper and graphite. The EDM is performed by varying different process parameters like voltage (V), discharge current (Ip), duty cycle (τ), and pulse-on-time (Ton). The surface roughness parameters like Ra, Rt, and Rz are measured by the use of surface roughness measurement machine. To reduce the number of experiments, design of experiment (DOE) approach like Taguchi's L27 orthogonal array has been used. The surface properties of the EDM specimen are optimized by desirability function approach, TOPSIS and VIKOR method, and the best parametric setting is reported for the EDM process. All the optimization techniques convergence to the same optimal parametric setting. The type of tool is the most significant parameter followed by discharge current and voltage. Better surface finish of EDM specimen is produced with lower level of parametric setting along with the use of AlSiMg RP electrode during EDM.

A New Approach in Surface Roughness and Roundness Improvement in Wire Electrical Discharge Turning Based on Statistical Analyses

2006 ◽  
Author(s):  
Aminollah Mohammadi ◽  
Alireza Fadaei Tehrani ◽  
Davoud Karimi ◽  
Ehsan Emanian
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Machining Parameters ◽  
Wire Edm ◽  
Analysis Method ◽  
Signal To Noise ◽  
New Approach ◽  
Good Improvement ◽  
Level Of Importance ◽  
Edm Process

In this paper, the effects and optimization of machining parameters on surface roughness and roundness in turning by wire EDM process are investigated. Surface roughness and roundness, were chosen, as the machining parameters to verify the process. In addition, power, time-off, voltage, servo, wire speed, wire tension and rotational speed were adopted for evaluation by Taguchi method. A L18 (21 × 37) Taguchi standard orthogonal array is chosen for the design of experiments. The level of importance of the machining parameters on the surface roughness and roundness is determined by using analysis of variance (ANOVA). The optimum machining parameters combination was obtained by using the analysis of signal-to-noise (S/N) ratio. The variation of surface roughness and roundness with machining parameters is mathematically modeled by using regression analysis method. Finally, experimentation was carried out to identify the effectiveness of the proposed method. A good improvement was obtained.

Optimization of Recast Layer Thickness and Surface Roughness in the Wire EDM Process of AISI H13 Tool Steel Using Taguchi and Fuzzy Logic

2014 ◽  
Vol 493 ◽  
pp. 529-534 ◽  
Author(s):  
Pathya Rupajati ◽  
Bobby Oedy Pramoedyo Soepangkat ◽  
Bambang Pramujati ◽  
H.C. Kis Agustin
Keyword(s):  
Surface Roughness ◽  
Fuzzy Logic ◽  
Taguchi Method ◽  
Layer Thickness ◽  
Fuzzy Reasoning ◽  
Recast Layer ◽  
Performance Characteristics ◽  
Wire Edm ◽  
Recast Layer Thickness ◽  
Edm Process

In this study, the optimization of recast layer thickness and surface roughness (SR) simultaneously in a Wire-EDM process by using Taguchi method with fuzzy logic has been applied. The Wire-EDM process parameters (arc on time, on time, open voltage, off time and servo voltage) were optimized with considerations of multiple performance characteristics, i.e., recast layer thickness and SR. Based on the Taguchi method, an L18 mixed-orthogonal array table was chosen for the experiments. Fuzzy reasoning of the multiple performance characteristics has been developed based on fuzzy logic, which then converted into a fuzzy reasoning grade or FRG. As a result, the optimization of complicated multiple performance characteristics was transformed into the optimization of single response performance index. Experimental results have shown that machining performance characteristics of Wire-EDM process can be improved effectively through the combination of Taguchi method and fuzzy logic.

Development of the Cylindrical Wire Electrical Discharge Machining Process, Part 2: Surface Integrity and Roundness

2002 ◽  
Vol 124 (3) ◽  
pp. 708-714 ◽  
Author(s):  
Jun Qu ◽  
Albert J. Shih ◽  
Ronald O. Scattergood
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Material Removal ◽  
Average Surface Roughness ◽  
Wire Edm ◽  
Average Surface ◽  
Arithmetic Average ◽  
Edm Process ◽  
Wire Feed ◽  
Cylindrical Wire

This study investigates the surface integrity and roundness of parts created by the cylindrical wire EDM process. A mathematical model for the arithmetic average surface roughness on the ideal surface of a cylindrical wire EDM workpiece is first derived. Effects of wire feed rate and part rotational speed on the surface finish and roundness for brass and carbide work-materials at high material removal rates are investigated. The pulse on-time and wire feed rate are varied to explore the best possible surface finish and roundness achievable by the cylindrical wire EDM process. This study has demonstrated that, for carbide parts, an arithmetic average surface roughness and roundness as low as 0.68 and 1.7 μm, respectively, can be achieved. Surfaces of the cylindrical EDM parts were examined using Scanning Electron Microscopy (SEM) to identify the macro-ridges and craters on the surface. Cross-sections of the EDM parts are examined using the SEM to quantify the sub-surface recast layers and heat-affected zones under various process parameters. This study has demonstrated that the cylindrical wire EDM process parameters can be adjusted to achieve either high material removal rate or good surface integrity and roundness.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

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