scholarly journals Experimental Investigation on Material Transfer Mechanism in WEDM of Pure Titanium (Grade-2)

2013 ◽  
Vol 2013 ◽  
pp. 1-20 ◽  
Author(s):  
Anish Kumar ◽  
Vinod Kumar ◽  
Jatinder Kumar
Keyword(s):  
Experimental Investigation ◽  
Pure Titanium ◽  
Transfer Mechanism ◽  
Free Form ◽  
Machining Parameters ◽  
Material Transfer ◽  
X Ray ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

This research work mainly focused on experimental investigation on material transfer mechanism in WEDM of pure titanium. The effects of machining parameters such as pulse on time, pulse off time, peak current, spark gap voltage, wire feed, and wire tension on the material removal rate (MRR), overcut, and surface roughness for pure titanium in WEDM process were explored. The selected machined samples were analyzed using energy dispersive X-ray analysis, scanning electron microscope, and X-ray diffraction techniques. It was observed from the results that a significant material transfer occurred from the dielectric, as well as tool, electrode on the work surface either in free form and/or in compound form. Also the multiresponse optimization of process parameters was done using desirability approach. The predictions from this model were validated by conducting experiments.

Investigation of Micro-Cracks Susceptibility on Machined Pure Titanium Surface in WEDM Process

2016 ◽  
Vol 16 (2) ◽  
pp. 123-139 ◽  
Author(s):  
Anish Kumar ◽  
Vinod Kumar ◽  
Jatinder Kumar
Keyword(s):  
Titanium Dioxide ◽  
Crack Formation ◽  
Research Work ◽  
Pure Titanium ◽  
Machined Surface ◽  
X Ray ◽  
Micro Cracks ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

AbstractThis research work presents a comprehensive and quantitative analysis of micro-crack formation, in terms of length and number of micro-cracks formed on the machined surface of pure titanium. The effect of processing parameters on micro-crack formation was studied through scanning electron microscope. The results indicate that the micro-crack formation is the best represented in terms of average crack length. Statistical analysis of the results shows that pulse on time, pulse off time and peak current significantly deteriorate the microstructure of machined surfaces which produces the deeper, wider globules of debris and micro cracks. The compounds like titanium dioxide (rutile) (TiO2), (TiO0.325), Ti2O3, Ilmenite (Fe2Ti4O), titanium carbides (TiC) and copper titanium dioxide (Cu3TiO4) were formed due to phase transformations that were analyzed through X-ray diffraction and energy dispersive X-ray method.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Multiple Performance Optimization in WEDM Parameters Using Grey Relational Analysis

2015 ◽  
Vol 813-814 ◽  
pp. 357-361
Author(s):  
T. Rajmohan ◽  
Gopi Krishna ◽  
Ankit Kumar Singh ◽  
A.P.V. Swamy Naidu
Keyword(s):  
Grey Relational Analysis ◽  
Performance Characteristics ◽  
304L Stainless Steel ◽  
Machining Parameters ◽  
Relational Analysis ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time

In this investigation, a new approach is based on Grey Relational Analysis and Taguchi method to optimize the machining parameters with multi performance characteristics in WEDM of 304L SS. Experiments are conducted using Taguchi Quality Concept, L9,3-level orthogonal array was chosen for experiments .The WEDM parameters namely pulse-on time (TON), pulse-off time (TOFF), and wire feed (WF) on material removal rate (MRR) .The Grey Relational Analysis with multiple performance characteristics indicates that the pulse-on time (TON), pulse-off time (TOFF) are the most significant factors . The optimum machining parameters have been identified by Grey relational analysis and significant contribution of parameters can be determined by analysis of variance (ANOVA). The confirmation test is also conducted to validate the test result. The results from this study will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine 304L Stainless Steel.

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 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%.

A Study on Working Process of Wire-EDM by Using Two Different Dielectric Fluids on HCHCr Alloy Steel

2016 ◽  
Vol 852 ◽  
pp. 212-217 ◽  
Author(s):  
S.K. Dinesh Kumar ◽  
R. Selvanayagam ◽  
M. Sivakumar ◽  
S. Krishnaraj
Keyword(s):  
Alloy Steel ◽  
Metal Removal ◽  
Removal Rate ◽  
Electrical Discharge Machine ◽  
Machining Parameters ◽  
Machining Performance ◽  
Taguchi Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

Wire electrical discharge machine (WEDM) is extensively used in machining of conductive material where precision is of prime importance. Machining operation in WEDM is treated as a challenging one because improvement of more than one Machining performance characteristics are sought to obtain precision work. This project illustrates the implementation of Taguchi technique to select the best optimal machining parameters of WEDM process using Copper powders. In general the machining parameters namely metal removal rate and the surface roughness are determined in WEDM process. The machining material chosen for the experiment is HCHCr alloy steel. Experiments were conducted as per Taguchi’s L18 orthogonal array under different cutting conditions of pulse on-time, pulse off-time, current and frequency and the results are compared. The level of significance of the machining parameters on the output characteristics is identified by Analysis of Variance. Finally this research concludes that the copper powder suspended demineralized water when used as dielectric gives higher MRR and lower Ra. Taguchi optimization is carried out to find the best combination of machining parameters to obtain the desired result

Optimization of Wire Electrical Discharge Machining Parameters of Activated Carbon Reinforced Aluminium Composite

2020 ◽  
Vol 979 ◽  
pp. 3-9
Author(s):  
G. Ramanan ◽  
M.Madhu Kiran Reddy ◽  
V. Manishankar
Keyword(s):  
Activated Carbon ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Influential Factors ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The quality of machining through process parameters on the responses in wire electrical discharge machining (WEDM) is studied. This paper discusses the optimization of parameters of a process in WEDM machining with the application of the desirability approach on the basis of response surface methodology (RSM). Pulse on time, servo speed rate, discharge current, and pulse off time have been considered as influential factors. The established experimental data of AA7075 aluminium reinforced with 9% of activated carbon composite to analyze the process parameter effects on responses, like material removal rate (MRR) and surface roughness (SR). After machining multiple regression analysis is used to find the interaction among the process parameters is obtained. The optimal parameters were found using the desirability optimization methodologies as 10.43mm3/min and 3.32μm respectively. The performance of the optimization test confirmed that the proposed method in this study effectively improves the performance of the WEDM process.

scholarly journals Investigating the Influence of Process Parameters of ZNC EDM on Machinability of A6061/10% SiC Composite

2013 ◽  
Vol 2013 ◽  
pp. 1-8 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Thermal Analysis ◽  
Optical Microscopy ◽  
Process Parameters ◽  
Al Alloy ◽  
Machining Parameters ◽  
Machining Performance ◽  
X Ray ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

A6061/10% SiC composite has been fabricated by mechanical stir casting process. Fabricated composite has also been characterized through optical microscopy, X-ray diffraction analysis (XRD), scanning electron microscopy analysis (SEM) with energy dispersive X-ray techniques (EDX), and thermogravimetric/differential thermal analysis (TG/DTA). The composite has been experimentally investigated for its machinability usingZ-axis numerically controlled (ZNC) electrodischarge machining (EDM) process. The effects of the four process parameters, namely, current, gap voltage, pulse-on time, and pulse-off time are investigated on material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR) by varying one parameter at a time approach. Optical microscopy and SEM analysis revealed the uniform distribution of SiC particles in aluminum matrix phase. XRD investigation corroborated the elemental composition of 6061 Al alloy and reinforcement particles. Thermal analysis shows stability of composite upto 650°C. The machinability characteristics, namely, MRR, TWR, and SR have been interpreted using graphical representations. The study indicates that all the machining parameters affect the machining performance of A6061/10% SiC composite. Optimum machining performance has been realized at the lower setting of current and pulse-on time and the optimum setting of pulse-off time and gap voltage.

Multiple Performance Optimization in WEDM Parameters Using Desirability Analysis

2015 ◽  
Vol 813-814 ◽  
pp. 352-356 ◽  
Author(s):  
S. Vijaya Bhaskar ◽  
T. Rajmohan ◽  
G.R. Giri Sesha Sai ◽  
G. Sandeep Kumar Reddy
Keyword(s):  
Surface Roughness ◽  
Analysis Of Variance ◽  
Process Parameters ◽  
Performance Optimization ◽  
Function Analysis ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Desirability Function Analysis ◽  
Wedm Process

In this article, the effect of wire electrical discharge machining (WEDM) parameters such as pulse-on time (TON), pulse-off time (TOFF), and wire feed (F) on material removal rate (MRR) and surface roughness in metal matrix composites (MMCs) consisting of aluminium alloy (A1356) silicon carbide (SiCp) and Mica is discussed. The Al 356 is reinforced with SiCp and Mica in the form of particulates. The experiments are carried out as per design of experiments approach using L9 orthogonal array. The optimum machining parameters have been identified by a composite desirability value obtained from desirability function analysis as the performance index, and significant contribution of parameters can then be determined by analysis of variance (ANOVA). Confirmation test is also conducted to validate the test result. Experimental results have shown that machining performance can be improved effectively through this approach. The results were analysed using analysis of variance and response graphs. It is found that different combinations of WEDM process parameters are required to achieve higher MRR and minimum surface roughness for composites. These results will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine MMCs of Al 356 reinforced with SiC and Mica.

scholarly journals Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1105
Author(s):  
Nagarajan Lenin ◽  
Mahalingam Sivakumar ◽  
Gurusamy Selvakumar ◽  
Devaraj Rajamani ◽  
Vinothkumar Sivalingam ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Fly Ash ◽  
Process Control ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Machining Parameters ◽  
Control Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated through the stir casting process by varying the wt% of reinforcements from 3 to 9. In the machinability studies, the WEDM process control parameters such as gap voltage, pulse-on time, pulse-off time, and wire feed were varied to analyze their effects on machining performance including volume removal rate and surface roughness. The WEDM experiments were planned and conducted through the L27 orthogonal array approach of the Taguchi methodology, and the corresponding volume removal rate and surface roughness were measured. In addition, the multi-parametric ANOVA was performed to examine the statistical significance of the process control parameters on the volume removal rate and surface roughness. Furthermore, the spatial distribution of the parameter values for both the responses were statistically analyzed to confirm the selection of the range of the process control parameters. Finally, the quadratic multiple linear regression models (MLRMs) were formulated based on the correlation between the process control parameters and output responses. The Grass–Hooper Optimization (GHO) algorithm was proposed in this work to identify the optimal process control parameters through the MLRMs, in light of simultaneously maximizing the volume removal rate and minimizing the surface roughness. The effectiveness of the proposed GHO algorithm was tested against the results of the particle swarm optimization and moth-flame optimization algorithms. From the results, it was identified that the GHO algorithm outperformed the others in terms of maximizing volume removal rate and minimizing the surface roughness values. Furthermore, the confirmation experiment was also carried out to validate the optimal combination of process control parameters obtained through the GHO algorithm.

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