A New Wire Electrode for Improving the Machining Characteristics of High-Volume Fraction SiCp/Al Composite in WEDM

Chen, Zhi; Zhou, Hongkang; Wu, Cheng; Zhang, Guojun; Yan, Hongjie

doi:10.3390/ma15124098

Cited by 14 publications

(9 citation statements)

References 67 publications

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“…The average of all three values was then selected. Equation (1) was used to determine the MRR after the machining time was measured using a stopwatch [44,45].…”

Section: Methodsmentioning

confidence: 99%

Advanced Optimization of Surface Characteristics and Material Removal Rate for Biocompatible TI6Al4V using WEDM Process with BBD and NSGA II

Nagadeepan¹,

Jayaprakash²,

Senthilkumar³

2023

Preprint

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Machining titanium alloy (Ti6Al4V) used in orthopedic implants by conventional metal cutting processes is challenging due to excessive cutting forces, low surface integrity and tool wear. To overcome these difficulties and for ensuring high-quality products, various industries employ wire electrical discharge machining (WEDM) for precise machining of intricate shapes in titanium alloy. The objective is to make WEDM machining parameters as efficient as possible for machining the bio-compatible alloy Ti6Al4V using box-behnken design (BBD) and Non-dominated Sorting Genetic Algorithm II (NSGA II). A quadratic mathematical model is created to represent the productivity and the quality factor (MRR and surface roughness) in terms of varying input parameters, such as pulse active (Ton) time, pulse inactive (Toff) time, peak amplitude (A) current and applied servo (V) voltage. The established regression models and related prediction plots provide a reliable approach for predicting how the process variables affect the two responses viz MRR and SR. The effects of four process variables on both the responses were examined, and the findings revealed that the pulse duration and voltage has a major influence on the rate at which material is removed (MRR) whereas pulse duration influence quality (SR). The trade-off between MRR and SR, when significant process factors are included emphasizes the need for a reliable multi-objective optimization method. The intelligent metaheuristic optimization method named non-dominated sorting genetic algorithm II (NSGA II) is utilized to provide pareto optimum solutions in order to achieve high material removal rate (MRR) and low surface roughness (SR).

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“…The average of all three values was then selected. Equation (1) was used to determine the MRR after the machining time was measured using a stopwatch [44,45].…”

Section: Methodsmentioning

confidence: 99%

Advanced Optimization of Surface Characteristics and Material Removal Rate for Biocompatible TI6Al4V using WEDM Process with BBD and NSGA II

Nagadeepan¹,

Jayaprakash²,

Senthilkumar³

2023

Preprint

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“…%) and Mg (0.05 wt. %) to increase the mechanical strength of brass alloys [6]. Nickel elements with a purity of >99 % and metallic aluminum powder with a purity level of >98 % are selected by the metal industry in Turkey.…”

Section: Introductionmentioning

confidence: 99%

Comparison of the accuracy of OES and EDX tests on nickel dissolving in brass casting

Erwin,

Suprapto,

Sugiarto

et al. 2024

Eureka: PE

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Brass alloys contain the dangerous element lead. Material engineering is carried out to reduce the lead element in brass alloys and add nickel elements as a substitute for lead elements by the casting process. The phenomenon analyzed in this study explains comparing the accuracy level of OES and EDX test results on nickel dissolution in brass casting, especially in adding nickel elements. So that researchers can compare the decrease in the percentage of nickel element composition in the OES test results. At the same time, there is an increase in nickel element composition in the EDX test results. The brass dissolution process uses an electric furnace with an initial temperature of 526 °C. Elemental nickel was introduced into brass solution and dissolved elemental nickel at 978 °C for 120 min for a variation of 1 %, 2 %, 3 %, and for 180 min for a variation of 4 %. The composition of alloying elements is tested using OES and EDX. The dissolution process of brass with the addition of nickel elements tested with OES decreased from 1 % nickel elements to 0.650 %, 2 % to 1.630 %, 3 % to 2.046 %, and 4 % to 2.810 %. Meanwhile, from the EDX test results, there was an increase in the composition of nickel elements from nickel 1 % to 1.41 %, 2 % to 2.57 %, 3 % to 3.41 %, and 4 % to 4.49 %. Brass alloys with nickel elements added decreased due to slag produced during the dissolution process of nickel elements in molten brass from the test results using OES. EDX testing results in an increase in the percentage of nickel elemental composition. The results of the OES test validation of the mechanical properties of adding nickel elements to brass alloys can be considered because the material's strength is still under the reference UNS C89550. This research contribution resulted in an effective and efficient test method with OES to analyze the elemental composition in brass alloys to which nickel elements have been added

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“…They concluded that there was a 35% increase in the wire feed rate along with a 40% reduction in wire consumption using coated wire compared to uncoated wire. Zei Chen [15] carried out an investigation on improving the characteristics of WEDM, and a comparison was made between copper wire and zinc-coated WEDM, and a 21.18% reduction in the wire wear rate along with a 16.67% improvement in the surface roughness were reported. Ruma et al [16] discussed the effects of three wire electrodes composed of plain brass wire, silver-coated brass wire, and zinc-coated wire on the machining of maraging 300 steel.…”

Section: Introductionmentioning

confidence: 99%

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Kosaraju¹,

Bobba²,

Salkuti

2023

Materials

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Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.

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A New Wire Electrode for Improving the Machining Characteristics of High-Volume Fraction SiCp/Al Composite in WEDM

Cited by 14 publications

References 67 publications

Advanced Optimization of Surface Characteristics and Material Removal Rate for Biocompatible TI6Al4V using WEDM Process with BBD and NSGA II

Advanced Optimization of Surface Characteristics and Material Removal Rate for Biocompatible TI6Al4V using WEDM Process with BBD and NSGA II

Comparison of the accuracy of OES and EDX tests on nickel dissolving in brass casting

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

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