A Critical Review on Optimization of WEDM Process Using Taguchi Array

Wire electrical release machining (WEDM) innovation has developed at special case rate since it was first applied over long term prior.WEDM is a widely recognized unconventional material cutting process used to manufacture components with complex shapes and profiles of hard materials. In this thermal erosion process, there is no physical contact between the wire tool and work materials. Wire Electrical Discharge Machining (WEDM) is getting more tasks in fields like dies, punches, aero and many more. It is the very difficult task to get optimum process parameters for higher cutting efficiency. In WEDM process rough machining gives lesser accuracy and finish machining gives fine surface finish, but it reduces the machining speed. This review involves process, principle, literature and applications of WEDM using Taguchi array. Keywords: WEDM; Materials; Machine; Cutting efficiency; Optimization process.

Multi-Independent Optimization while Turning of Inconel-600 alloy using Grey Interactive Exploration

This investigation effort offers multi-quality attributes optimization while turning of Inconel-600 superalloy. Taguchi's L9 orthogonal planning is implemented to review the upshot of governing aspects such as machining speed, feed rate, and depth of cut on vibrations and surface roughness (SR). To heighten all the three leading variables, the grey interactive exploration (GIE) is implemented. The grey interactive rating (GIR) is practiced as a multi-quality exclusive key (MQEK). The finest formation of central variables acquired from the investigational grades is cutting speed 500 m/min, feed rate 0.22 mm/rev and depth of cut 0.5 mm. ANOVA scrutiny signposts that feed rate is a crucial variable relating to the superiority yields. Products of endorsement pilots display that the ideal foremost variables developed the grey interactive rating from 0.6932 to 0.8138 for the numerous retorts. Scanning Electron Microscopic (SEM) scrutiny of cutting tool spectacles that fracture, chipping, abrasion and adhesion are the primary wear phenomena.

Effect of Machining Limiting Factors on Drilling Progress during Spark Assisted Chemical Engraving (SACE): General Trends

Spark Assisted Chemical Engraving (SACE) is a micro-machining technology for non-conductive materials, mainly glass, based on thermal assisted etching. Generally, during SACE, drilling proceeds at a fast rate reaching 100 µm/s for the first 100 µm and then it slows down for depths higher than 300 µm. While several techniques have been proposed to establish faster drilling, they mainly rely on tuning the machining parameters to enhance the machining performance. However, with this approach machining parameters need to be constantly tuned to achieve certain machining performance depending on the size of the tool and the features needed. Therefore, this necessitates further work to enhance understanding regarding the SACE machining process fundamentals in order to enhance machining speed and quality. Since SACE is a thermal assisted etching process, both local heating and flushing of electrolyte in the machining zone are required. However, to the authors’ knowledge there is not any study that attempts to analyze the effect of each of these machining limiting factors on the machining performance. This work attempts to clarify the effect of each flushing and heating on the drilling progress for hole depths higher than 100 microns. It therefore provides a deeper understanding of the fundamentals of the SACE machining process.

Influence of Turn-Rolling on the Residual Stresses and Microstructure of C45E and the Effects on Fatigue Life under Cyclic Loading

The microstructure and the residual stress state have a significant influence on the service life of the component. The deep rolling process already enables a significant increase in the strength and service life of highly stressed components. By using the hybrid manufacturing process of turn rolling, the edge zone properties can be influenced to such an extent that the service life is further increased compared to conventional deep rolling. In addition to a change in the residual stress state, the use of the turning process temperature also leads to a significant grain refinement in the edge zone area, which has a positive effect on the component service life. This modification of the edge zone can be significantly influenced by the machining speed.

Using Response Surface Methodology of Deep Hole Electrical Discharge Machining Study of Nickel-Base Alloy Inconel-718

The blades in the high-pressure turbine section of engines of modern aerospace and defense industries need to be drilled for pressurization. The milling and drilling of nickel-base material Inconel-718 are likely to create tool wear and tear, so the drilling process of milling is replaced by deep hole electrical discharge machining (EDM) extensively. However, the EDM creates reaming or overcut phenomenon, so reducing overcut by parameter optimization is an important study. This study used will use response surface methodology to establish the influencing factors of machining parameters in the hole enlargement and machining speed. The experimental results show that the main influencing factor in the nickel-base alloy deep hole EDM is the discharge voltage (V), the secondary factor is the discharge current (I). The hole enlargement of processed hole without optimization is 60um~100um. The DOE is used for hole enlargement measurement and machining speed measurement to design important parameters, and to predict experiment data analysis. The half normal probability graph, Pareto chart and Analysis of variance (ANOVA) are used to learn about the significant factors of parameters and the influence of interaction. The outlet value of optimized parameters is relatively uniform, and the hole morphology is relatively free of residue stacking. Finally, the inlet and outlet results are improved by 17.9% compared with the original parameters. The optimization parameter value predicted by the fitted model is 0.0392mm, and the optimized upper and lower holes validation experiment machining error is 0.0380mm, and the values are quite close, proving that this prediction model is accurate. The model prediction of this DOE can enhance the applied technology of deep hole EDM for nickel-base alloy.

Multi-Objective Optimization in WEDM of Al 7075 Alloy Using TOPSIS and GRA Method

In this research study, Taguchi grey relational analysis (GRA) has been coupled with the technique for order of preference by similarity to ideal solution (TOPSIS) to optimize the multi-performance characteristics in WEDM of Al 7075 alloy. The influence of process factors such as pulse duration (Ton), pulse interval (Toff), flushing pressure (Fp), and servo voltage (Sv) on output responses machining speed (Vc) and corner inaccuracy (Ce) have been considered. The analysis of variance (ANOVA) for the grey relational grade (GRG) and order of preference value generated by TOPSIS have been carried out to justify the optimal results. The recommended input factor settings are found to be Ton = 1.1 µs, Toff = 20 µs, Fp = 9 kg/cm2, and Sv = 20 volt from TOPSIS, and from GRA is Ton = 1.1 µs, Toff = 10 µs, Fp = 12 kg/cm2, and Sv = 40 volt. Finally, surface roughness and surface topography evaluation have been carried out in-depth understanding of influencing factors.

Optimization of compressed air assisted-turning-burnishing process for improving machining quality, energy reduction and cost-effectiveness

The burnishing process is used to enhance the machining quality via improving the surface finish, surface hardness, wear-resistance, fatigue, and corrosion resistance, and it is mostly used in aerospace, biomedical, and automotive industries to improve reliability and performance of the component. The combined turning and burnishing process is therefore considered as an effective solution to enhance both machining quality and productivity. However, the trade-off analysis between energy consumption, surface characteristics, and production costs has not been well-addressed and investigated. This study presents an optimization of the compressed air assisted-turning-burnishing (CATB) process for aluminum alloy 6061, aimed to decrease the energy consumption as well as surface roughness and to enhance the Vicker hardness of the machined surface. The machining parameters for consideration include the machining speed, feed rate, depth of cut, burnishing force, and the ball diameter. The improved Kriging models were used to construct the relations between machining parameters and the technological response characteristics of the machined surface. The optimal machining parameters were obtained utilizing the desirability approach. The energy based-cost model was developed to assess the effectiveness of the proposed CATB process. The findings showed that the selected optimal outcomes of the depth of cut, burnishing force, diameter, feed rate, and machining speed are 0.66 mm, 196.3 N, 8.0 mm, 0.112 mm/rev, and 110.0 m/min, respectively. The energy consumption and surface roughness are decreased by 20.15% and 65.38%, respectively, while the surface hardness is improved by 30.05%. The production cost is decreased by 17.19% at the optimal solution. Finally, the proposed CATB process shows a great potential to replace the traditional techniques which are used to machine non-ferrous metals.

Study on Wire Electrochemical Machining of Nickel Base Alloy Using Fine Wire Electrode

Nickel-based alloys represented by Inconel are materials with excellent high-temperature characteristics, and are widely used in the aerospace industry, such as aircraft and rocket engine parts. On the other hand, it is known as a typical difficult-to-cut material. Furthermore, in machining and electric discharge machining (EDM), the machining speed is slow and tool or electrode wear is a big problem. Meanwhile, electrochemical machining (ECM) using electrochemical reaction is not affected by the hardness of the material, does not generate a heat-affected layer on the workpiece surface, and has no tool wear. So, it is considered that ECM is suitable for machining difficult-to-cut materials. Therefore, in this study, focusing on the nickel-based alloy Inconel718 (Alloy718), we conducted a machining experiment using NaNO3 aqueous solution by wire ECM using a thin wire (mainly tungsten) as a tool electrode, and investigated the ECM characteristics. Wire ECM can be machined like wire EDM, and high-efficiency machining is possible by using a pulse power supply. As a result, it was found that increasing the voltage, electrolyte concentration, electrolyte supply pressure, and diameter of wire increases the current flowing between the electrodes and has the effect of promoting machining. In addition to simple cutting, the possibility of being effective not only for grooving but also for cutting complex shapes was shown.

Optimization of Process Parameter by using CNC Wire Electrical Discharge Machine through Taguchi Method

Wire Electrical Discharge Machining (WEPSPDM) is utilizedin industries to manufacture components of conductive strong metal with complicated shape, greater tolerance and precision. A review of the literature exposes that most of the research work has been intended for towards the optimization of WEDM operation and modeling of the process. Conventional wire electrode has been developed to a brass wire from a copper wire and finally to zinc coated wire on the brass, steel or copper wire core, by which more advanced WEDM, is realized in terms of better machining speed and accuracy. To examine the parameters likePeak Current (Ip ), Time of Pulse ON (Ton), Time of Pulse OFF (Toff), etc. by the optimization of WEDM operation and modeling of the process during micro slit machining. Analyzed the results and optimize the process parameter conditions for maximum MRR (g/min), and surface roughness based on Taguchi’s Methodology. The ANOVA analysis indicates the significant factors for maximization of MRR, improvement of Surface Roughness and regression analysis. By the research work, it has been concluded that the MRR reduces with raise in Time of Pulse OFF (Toff) and Set Voltage of spark gap (SV) besides Material Removal Rate (MRR) increases with escalating in Time of Pulse ON (Ton) and PC (IP).