An investigation on effects of wire-EDT machining parameters on surface roughness of INCONEL 718

Naik, Gajanan M.; Anjan, B.N.; Badiger, Ravindra I.; Bellubbi, Sadashiv; Mishra, Dinesh Kumar

doi:10.1016/j.matpr.2020.03.031

Cited by 6 publications

(6 citation statements)

References 12 publications

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“…Commonly, based on the process parameters and their levels, more number of trials needs to be conducted as per traditional strategy. The intention behind selection of Taguchi-OA is to afford for the optimum level of each parameter so as to decide the relative contribution of individual parameter using ANOVA [13,25]. The experimental design in the present work was planned using Minitab-17 software which resulted in 27 trials to be performed.…”

Section: Genichi Taguchi Methodsmentioning

confidence: 99%

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Bellubbi

Sathisha

Mallick³

2021

Silicon

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In this work, machining of microchannel in silica glass was successfully carried out using electro chemical discharge machining (ECDM) process. The experiments were planned according to L27 orthogonal array with applied voltage, stand-off distance (SOD), electrolyte concentration, pulse frequency and pulse-on-time (TON) as control factors. The material removal rate (MRR), overcut (OC) and tool wear rate (TWR) were considered as response characteristics. In this study the effects of control parameters on MRR, OC and TWR have been investigated. The multi-objective optimization of ECDM was carried out through grey relational analysis (GRA) method. Optimal combination of process parameters achieved from GRA was 45V applied voltage, 25wt.% electrolyte concentration, 1.5mm SOD, 400Hz pulse frequency and 45μs TON. ANOVA for GRG study revealed that the applied voltage (70.33%) was most significant factor affecting output responses followed by electrolyte concentration (11.69%), pulse frequency (4.98%) and SOD (4.13%). Furthermore, the regression equations were formulated for the optimum combination to predict the collaboration and higher-order effects of the control parameters. In addition confirmation test was conducted for the optimal setting of process parameters and the comparison of experimental results exhibited a good agreement with predicted values. The microstructural observation of machined surface for the optimum combination was carried out.

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Section: Genichi Taguchi Methodsmentioning

confidence: 99%

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Bellubbi

Sathisha

Mallick³

2021

Silicon

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“…This work L Gupta (2024) [14] Selvam (2023) [15] L Sadhana (2022) [16] L 9 Chary (2022) [17] L Paturi (2021) [18] L Saif (2021) [19] L 9 Naik (2021) [20] L Kumar, A. (2021) [21] L Kumar, U.…”

Section: Materials Removal Rate Energy Othermentioning

confidence: 99%

“…In the research conducted by Naik et al [20], the study explored the effects of different machining parameters on surface roughness in the Wire Electrical Discharge Texturing (WEDT) of INCONEL 718 super alloy. The investigated parameters included rotational speed, pulse on-time, pulse off-time, servo voltage, wire feed rate, and flushing pressure.…”

Section: Materials Removal Rate Energy Othermentioning

confidence: 99%

Optimization of Cutting Parameters for Energy Efficiency in Wire Electrical Discharge Machining of AISI D2 Steel

González-Rojas,

Miranda-Valenzuela,

Calderón-Najera

2024

Applied Sciences

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Improving energy efficiency in manufacturing processes is a critical global concern for the industry. Manufacturers strive to enhance energy efficiency across all manufacturing operations to remain competitive globally, aiming to reduce production times without compromising product quality. While there has been significant research characterizing energy efficiency and surface roughness in conventional processes like turning or milling, studies on unconventional manufacturing techniques are limited. This study focuses on optimizing a wire electrical discharge machining (WEDM) process to minimize energy consumption while maintaining surface roughness. Various cutting parameters, such as pulse on-time, pulse off-time, servo voltage, wire tension, wire speed, and wire voltage, were evaluated. Experiments were conducted using Taguchi’s methodology with a L27 orthogonal array, employing AISI D2 steel plates of 19 mm and 25 mm thickness as the machining material. The research identified that optimal parameters for reducing energy consumption and improving surface roughness included a pulse on-time of 10 s, pulse off-time of 11 s, servo voltage of 44 V, wire tension of 50 g-force, wire speed of 7 m per minute, and wire voltage of 9 volts. This combination led to an 8% reduction in energy consumption and a 1% enhancement in surface roughness compared to baseline values.

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“…They found that higher productivity and a better surface finish (i.e., lower values of "R a ") can be achieved with higher values of the SRS and wire inclination angle. Naik et al [18] studied the influence of variable parameters, namely, the spindle rotational speed, spark duration, spark-off duration, servo voltage, wire feed rate, and dielectric flow rate on surface roughness during the turning of an Inconel 718 cylindrical bar by the WEDT process. They found that the surface roughness decreased with an increase in the spark-off duration, servo voltage, and wire feed rate.…”

Section: Introductionmentioning

confidence: 99%

“…In this study, we successfully performed the micro-turning operation on a 6 mm diameter cylindrical titanium bar, which is smaller than the cylindrical bars employed in the previous work [14,16,18,31].…”

mentioning

confidence: 99%

Experimental Research on Surface Quality of Titanium Rod Turned by Wire Electrical Discharge Turning Process

Chaubey

Gupta

2023

Materials

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This paper reports the surface quality of a miniature cylindrical titanium rod/bar (MCTB) turned by the wire electrical discharge turning (WEDT) process using a zinc-coated wire of 250 µm diameter. The surface quality was mainly evaluated by considering the very important surface roughness parameters, i.e., the mean roughness depth. A Box–Behnken design (BBD) of the response surface methodology (RSM) based on 17 experimental runs was conducted, where the spark duration “Ton” was found as the most influential parameter affecting the mean roughness depth “RZ” of the miniature titanium bar. Further, using the grey relational analysis (GRA) technique of optimization, we obtained the least value of “RZ” 7.42 µm after machining a miniature cylindrical titanium bar with the optimum combination of WEDT’s variable parameters: Ton—0.9 µs, SV—30 V, and DOC—0.35 mm. This optimization led to a 37% reduction in the surface roughness Rz of the MCTB. The tribological characteristics of this MCTB were also found favorable after conducting a wear test. After completing a comparative study, we can claim that our results are better than those of the past research conducted in this area. The findings of this study are beneficial for the micro-turning of cylindrical bars made from a variety of difficult-to-machine materials.

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An investigation on effects of wire-EDT machining parameters on surface roughness of INCONEL 718

Cited by 6 publications

References 12 publications

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Multi Response Optimization of ECDM Process Parameters for Machining of Microchannel in Silica Glass Using Taguchi–GRA Technique

Optimization of Cutting Parameters for Energy Efficiency in Wire Electrical Discharge Machining of AISI D2 Steel

Experimental Research on Surface Quality of Titanium Rod Turned by Wire Electrical Discharge Turning Process

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