A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Khan, Sarmad Ali; Rehman, Mudassar; Farooq, Muhammad Umar; Ali, Mohammad; Naveed, Rakhshanda; Pruncu, Catalin I.; Ahmad, Waheed

doi:10.3390/met11050816

Cited by 27 publications

(20 citation statements)

References 37 publications

(65 reference statements)

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“…Multiobjective optimization is the best way to acquire an optimal combination of parameters for contradictory responses [55]. Desirability is an effective way to simultaneously optimize the responses [56,57].…”

Section: One-step Sustainabilitymentioning

confidence: 99%

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Javid

Jahanzaib

Jawad

et al. 2021

Int J Adv Manuf Technol

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The requirement of cost-effective and ecological production systems is crucial in the competitive market. In this regard, the focus is shifted towards sustainable and cleaner machining processes. Besides the clean technologies, effective parametric control is required for machining materials (such as High Strength Low Alloy Steels) specifically designed for high strength applications having superior physio-chemical properties. Therefore, the machinability complexities require optimized solutions to reduce temperature elevation and tooling costs and improve machining of these materials. Complying to the market needs, this research examines the effectiveness of nanofluid on tool life, wear mechanisms, surface roughness (Ra), surface morphology, and material removal rate (MRR) in turning of 30CrMnSiA (HSLA) using minimum quantity lubrication (MQL) and SiO2-H2O nanofluids (NF-MQL). A systematic investigation based on physical phenomena involved is carried out considering four process parameters (cutting speed (VC), feed rate (Fr), depth of cut (DOC), and mode of lubrication for machining. Fr is found as the vital parameter for surface roughness while MRR is highly influenced by DOC regardless of lubrication approach. One-step sustainability technique is applied, in which process variables used for roughing conditions are analogous to attain surface comparable to finished machining without compromising process efficiency and demonstrate its feasibility through optimal settings under NF-MQL. Multi-response optimization proved the NF-MQL machining condition as the best alternative which result in 28.34% and 5.09% improvements for surface roughness and MRR, respectively. Moreover, the use of SiO2 is recommended over MQL due to lower energy consumption, low tool wear, and better surface integrity, sustainable liquid, and related costs.

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Section: One-step Sustainabilitymentioning

confidence: 99%

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Javid

Jahanzaib

Jawad

et al. 2021

Int J Adv Manuf Technol

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“…As we mentioned earlier, the dependence of the efficiency of EDM processing on the size of the IEG has an extremum, whose position shifts towards the larger IEG with the increasing concentration of contaminants ɣ. . While it is hypothetically possible to solve the problem of continuously adjusting the IEG to the changing position of the extremum by estimating, with a large degree of uncertainty, the fraction of working pulses, one can use acoustic emission instead [94][95][96][97][98][99][100][101][102][103][104][105][106][107][108][109]. In earlier studies of the WEDM process, it was found that changes in the energy flows do not affect the position of the spectral maxima of VA signals and, thus, the amplitudefrequency pattern [110].…”

Section: Materials Removal Rate (Mrr) Of the Wedmmentioning

confidence: 99%

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

Grigoriev

Pivkin

Kozochkin

et al. 2021

Metals

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The field of applied wire electrical discharge machining (WEDM) is rapidly expanding due to rapidly increasing demand for parts made of hard-to-machine materials. Hard alloys composed of WC, TiC and Co are advanced cutting materials widely used in industry due to the excellent combination of hardness and toughness, providing them obvious advantages over other cutting materials, such as cubic boron nitride, ceramics, diamond or high-speed steel. A rational choice of the WEDM modes is extremely important to ensure the dimensional quality of the manufactured cutting inserts, while roughness of the machined surface on the cutting edge is of great importance with regards to the application of wear-resistant coatings, which increases tool life. However, the stock control systems of CNC WEDM machines, which are based on assessment of electrical parameters such as amperage and voltage, are unable to timely detect conditions at which a threat of wire breakage appears and to prevent wire breakage by stopping the electrode feed and flushing out the interelectrode gap (IEG) when hard alloys with high heat resistance and low heat conductivity, such as WC, TiC and Co composites, are being machined, due to the inability to distinguish the working pulses and pulses that expend a part of their energy heating and removing electroerosion products contaminating the working zone. In this paper, the physicomechanical nature of the WEDM of hard alloy WC 88% + TiC 6% + Co 6% was investigated, and the possibility of using acoustic emission parameters for controlling WEDM stability and productivity were explored. Acoustic emission (AE) signals were recorded in octave bands with central frequencies of 1–3 and 10–20 kHz. It was found that at the initial moment, when the dielectric fluid is virtually free of contaminants, the amplitude of the high-frequency component of the VA signal has its highest value. However, as the contamination of the working zone by electroerosion products increases, the amplitude of the high-frequency component of the AE signal decreases while the low-frequency component increases in an octave of 1–3 kHz. By the time of the wire breakage, the amplitude of the high-frequency component in the octave of 10–20 kHz had reduced by more than 5-fold, the amplitude of the low-frequency component in the octave of 1–3 kHz had increased by more than 2-fold, and their ratio, coefficient Kf, decreased by 12-fold. To evaluate the efficiency of Kf as a diagnostic parameter, the quality of the surface being machined was investigated. The analysis of residual irregularities on the surface at the electrode breakage point showed the presence of deep cracks and craters typical of short-circuit machining. It was also found that the workpiece surface was full of deposits/sticks, whose chemical composition was identical to that of the wire material. The presence of the deposits evidenced heating and melting of the wire due to the increased concentration of contaminants causing short circuits. It was also shown that the wire breakage was accompanied by the “neck” formation, which indicated simultaneous impacts of the local heating of the wire material and tensile forces. Due to the elevated temperature, the mechanical properties the wire material are quickly declining, a “neck” is being formed, and, finally, the wire breaks. At the wire breakage point, sticks/deposits of the workpiece material and electroerosion products were clearly visible, which evidenced a partial loss of the pulses’ energy on heating the electroerosion products and electrodes. A further increase in the contamination level led to short circuits and subsequent breakage of the wire electrode. It was shown that in contrast to the conventional controlling scheme, which is based on the assessment of amperage and voltage only, the analysis of VA signals clearly indicates the risk of wire breakage due to contamination of the working zone, discharge localization and subsequent short circuits. The monotonic dependence of WEDM productivity on AE parameters provides the possibility of adaptive adjustment of the wire electrode feed rate to the highest WEDM productivity at a given contamination level. As the concentration of contaminants increases, the feed rate of the wire electrode should decrease until the critical value of the diagnostic parameter Kf, at which the feed stops and the IEG flushes out, is reached. The link between the AE signals and physicomechanical nature of the WEDM of advanced cutting materials with high heat resistance and low heat conductivity in different cutting modes clearly shows that the monitoring of AE signals can be used as a main or supplementary component of control systems for CNC WEDM machines.

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“…In the manufacturing realm, there is much significance on dimensions verification in railway, aeronautical, defense, marine, and other sectors. Therefore, the accuracy of tools being used to fabricate many specialized parts is considered vital [14,15]. The tools are required for several mechanical works such as drawing, shaping, stamping, coining, blanking, forging, and general applications.…”

Section: Introductionmentioning

confidence: 99%

“…are certain challenges. However, several researchers have been studying problems concerning accuracy in the past [14]. For instance, copper, brass, aluminum, and graphite were employed to Fig.…”

Section: Introductionmentioning

confidence: 99%

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Reducing the geometrical machining errors incurred during die repair and maintenance through electric discharge machining (EDM)

Ishfaq

Farooq

Pruncu

2021

Int J Adv Manuf Technol

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The importance of geometrical accuracy can never be overruled in dies and molds which governs the dimensional precision of the parts being manufactured. The continuous use of such tooling requires repair and maintenance. Among the different processes used to upkeep the dimensional consistency of the tooling, machining is essentially required in most cases. The intricacy of the dies and molds’ cavities requires the use of electric discharge machining (EDM). However, in EDM it is challenging to develop control over the machined dimensions owing to the inherent issues of overcut/undercut. This aspect was not comprehensively investigated so far which is the core focus of this research. Three electrode materials, namely, copper, graphite, and tungsten carbide, which belong to the category of metals, nonmetals, and ceramics, respectively, have been compared for the said perspective on the comprehensive list of parametric variables. The results revealed that the average value of the axial errors is 2.5 times lesser in comparison to lateral dimensional errors. In the case of lateral dimensional errors, the electrode of graphite has proved to be a promising choice in comparison to the other two types of electrode materials, namely, copper and tungsten carbide. The copper electrode is noticed to be the most appealing option for reducing axial error (A.E). The mean A.E obtained with Cu electrode is 80.9% and 47.6% lower than that achieved in case graphite and tungsten carbide, respectively. Furthermore, the optimal parametric combination based on 7 variables has also been proposed using desirability analyses whose validity is proved during confirmation trials.

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A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Cited by 27 publications

References 37 publications

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Parametric analysis of turning HSLA steel under minimum quantity lubrication (MQL) and nanofluids-based minimum quantity lubrication (NF-MQL): a concept of one-step sustainable machining

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

Reducing the geometrical machining errors incurred during die repair and maintenance through electric discharge machining (EDM)

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