A study on cryogenically treated molybdenum wire electrode

Myilsamy, Sureshkumar; Boopathi, S.; Yuvaraj, D.

doi:10.1016/j.matpr.2021.02.049

“…The MRR of the near-dry WEDM process was comparatively lower than the conventional process due to the significant flush out of removed material from the workpiece. The WWR of the near-dry process is lower than conventional WEDM because heat dissipation from the wire is improved by increasing the thermal conductivity of cryogenic cooling wire [16]. The minimum WWR is promoting the life of reusable wire electrode.…”

Section: Wwr =mentioning

confidence: 99%

“…Cryo-treated wire electrodes, liquid nitrogen, and zinc-coated brass wires were investigated to reduce tool wear rate for the green environment [4], [13] to [15]. Recently, the electrical conductivity of cryocooled molybdenum wire is increased by cryogenic treatments [16]. However, it was found that no synchronized cryo-treated gas-liquid mixer in the near-dry EDM and WEDM process.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Boopathi¹,

Myilsamy²

2021

SV-JME

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In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

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“…The MRR of the near-dry WEDM process was comparatively lower than the conventional process due to the significant flush out of removed material from the workpiece. The WWR of the near-dry process is lower than conventional WEDM because the heat dissipation from the wire is improved by increasing the thermal conductivity of the cryogenic cooling wire [16]. The minimum WWR promotes the life of reusable wire electrode.…”

Section: Comparison Of Cryogenically Cooled Near-dry and Conventional Wedmmentioning

confidence: 99%

“…Cryo-treated wire electrodes, liquid nitrogen, and zinc-coated brass wires were investigated to reduce the tool wear rate for the green environment [4], [13] to [15]. Recently, the electrical conductivity of cryo-cooled molybdenum wire has been increased by cryogenic treatments [16]. However, no synchronized cryo-treated gas-liquid mixer was found in the near-dry EDM and WEDM process.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Sampath¹,

Myilsamy²

2021

SV-JME

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In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

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“…It was observed that very few researchers were strived on applying the cryogenic assisted dry and near-dry EDM experiments to accomplish better machining performances. Very recently, the electric conductivity, wire wear resistance of molybdenum wire electrode has been improved by cryogenic treatment [46,47]. However, as per the above literature, cryogenically cooled molybdenum WEDM experiments are yet not performed systematically.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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In this research, the mixing of compressed air with the minimum quantity of water is used as a dielectric medium and the cryogenically cooled molybdenum wire is used as a tool in wire-cut electrical discharge machining (WEDM) to encourage the eco-friendly production, called cryogenically cooled near-dry WEDM process. The nitrogen gas-cooled wire tool is utilized to cut the Inconel 718 alloy workpiece to prevent wire breakage and maintain enough electrical conductivity. The preliminary experiments were conducted to compare wet, dry, near-dry, and cryogenically cooled near-dry WEDM processes. It was revealed that cryogenic cooled near-dry WEDM is better performance than dry, near-dry WEDM except for the wet process. The systematic experiments of eco-friendly cryogenically cooled near-dry WEDM have been conducted to analyse the effect of input factors like spark current, pulse-width, pulse-interval, and mixing water flow rate on material removal rate (MRR) and surface roughness (SR) using Box–Behnken method. The fitted models and response surface graphs were developed to analyse the influences of input factors on each response parameter. It was concluded that MRR and SR of cryogenically cooled near-dry WEDM are increased by maximizing spark current, pulse-width, and flow rate, conversely, both responses were decreased by increasing pulse-interval. The technique for order of preference by similarity to ideal solution (TOPSIS) technique has been applied to predict the best combination of input factors for satisfying the optimal values of both responses.

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A study on cryogenically treated molybdenum wire electrode

Cited by 19 publications

References 13 publications

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

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