Improvement of the Machining Performance of the TW-ECDM Process Using Magnetohydrodynamics (MHD) on Quartz Material

Many microslits are typically manufactured on quartz substrates and are used to improve their industrial performance. The fabrication of microslits on quartz is difficult and expensive to achieve using recent traditional machining processes due to its hardness, electrically insulating nature, and brittleness. The key objective of the current study was to demonstrate the fabrication of microslits on quartz material through a magnetohydrodynamics (MHD)-assisted traveling wire-electrochemical discharge micromachining process. Hydrogen gas bubbles were concentrated around the entire wire surface during electrolysis. This led to a less active dynamic region of the wire electrode, which decreased the adequacy of the electrolysis process and the machining effectiveness. The test results affirmed that the MHD convection approach evacuated the gas bubbles more rapidly and improved the void fraction in the gas bubble scattering layer. Furthermore, the improvements in the material removal rate and length of the cut were 85.28% and 48.86%, respectively, and the surface roughness was reduced by 30.39% using the MHD approach. A crossover methodology with a Taguchi design and ANOVA was utilized to study the machining performance. This exploratory investigation gives an unused strategy that shows a few advantages over the traditional TW-ECDM process.

Modeling and Response Optimization of Traveling Wire Electro-Chemical Spark Machining of Borosilicate Glass Using Hybrid Approach

Traveling Wire Electro-Chemical Spark Machining (TW-ECSM) process is a new innovative thermal erosion-based machining process suitable for cutting electrically nonconductive materials using tool electrode in the form of wire. This article attempts experimental modeling of TW-ECSM process using a hybrid methodology comprising Taguchi methodology (TM) and response surface methodology (RSM). The experiments were carried out on borosilicate glass using L[Formula: see text] orthogonal array (OA) considering the input parameters like applied voltage, pulse on-time, pulse off-time, electrolyte concentration and wire feed velocity along with process performances such as material removal rate (MRR), surface roughness (R[Formula: see text] and kerf width (K[Formula: see text]. The interaction influence of input parameters on process performances was also discussed. Further, multi-objective optimization (MOO) of response performances of TW-ECSM process is executed using a coupled approach of grey relational analysis (GRA) and principal component analysis (PCA). The optimal process parameter setting illustrates the improvement of MRR by 171%, diminution of Ra and K[Formula: see text] by 27% and 8% against the initial parameter settings. Moreover, irregular cutting of kerf width and surface characteristics were also scrutinized using scanning electron microscope (SEM).

Magnetic Materials Used in the Magnetic Core Manufacture of Electrical Machines and Transformers

Two types of silicon iron steels, M400-65A non-oriented and MOH grain-oriented alloys were characterized using an industrial Brockhaus Single Strip Tester at two peak magnetic polarizations of 500 mT and 1000 mT in the frequency range from 10 Hz to 100 Hz. The samples were cut parallel to the rolling direction trough different cutting technologies, which are the classical mechanical-, then the non-conventional laser-, water-jet-and traveling wire electro-erosion methods. The loss separation concept was applied and the total energy losses, determined experimentally, for each sample were decomposed into hysteresis, classical (Foucault) and excess (anomalous) energy losses. A detailed analysis of each type of losses as a function of the frequency was made and the influence of the cutting technology was analyzed.