Analysis of Effects of Cutting Parameters of Wire Electrical Discharge Machining on Material Removal Rate and Surface Integrity

Tonday, Hulas Raj; Tigga, Anand Mukut

doi:10.1088/1757-899x/115/1/012013

Cited by 13 publications

(6 citation statements)

References 8 publications

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“…It suggests that positive polarity of the electrode and dielectric fluid are favored for the machining of titanium grade 7 alloy using WEDM process. Similar experimental results were found by other researchers [10], [12]- [13]. The regression models represent an established correlation between WEDM parameters with responses like MRR and Ra.…”

Section: Discussionsupporting

confidence: 89%

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Investigation on Surface Roughness and MRR in WEDM of Titanium Grade 7 (Ti-0.15Pd) Alloy using Statistical Techniques

Djanali¹

2023

JMechE

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Wire Electric Discharge Machining (WEDM) of Titanium grade alloys with coated electrodes has several advantages over the traditional machining process such as increased productivity, reduction of processing cost, and improved material properties. The main objective is to create a relationship between WEDM parameters such as Pulse-on (TON), Pulse-off (TOFF), and Indicated Power (IP) with surface roughness (Ra) and Material Removal Rate (MRR). In the present work, the performance of zinc-coated brass electrodes for WEDM of Titanium Grade-7 alloy was assessed and optimized with statistical technique. ANOVA analysis is used to analysis of the MRR and Ra and validated with regression. The ANOVA analysis results indicated that TON is the highest statistically significant and followed by TOFF and IP on MRR and surface roughness. The optimum combination of higher IP(6 A) and TON time(60 μs) and lower TOFF time (12 μs) is lucrative for a higher MRR of 8.5682 mm3/min and lower surface roughness of 1.66 μm. The SEM images showed homogeneous solidification, columnar grain structure, recast layer surface, and minor surface crack density were noticed at higher cutting conditions. The predicted model and confirmation test results were close to each other with minimum error (<5%), so the model is adequate.

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Section: Discussionsupporting

confidence: 89%

“…Tonday et al [13] analysed the machining parameters effect on MRR and surface integrity during WEDM of Ti-based alloy with copper electrode. The authors observed that the discharge current is the most vital parameter on machined surface characteristics and MRR.…”

Section: Introductionmentioning

confidence: 99%

Investigation on Surface Roughness and MRR in WEDM of Titanium Grade 7 (Ti-0.15Pd) Alloy using Statistical Techniques

Djanali¹

2023

JMechE

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“…Similarly, MRR increases with the decrease in T off value and increase in current for the effect of contour for current and T off . This is due to the fact that the number of spark decreases with an increase in pulse off time which thereby lowers MRR and discharge energy increase with an increase in current which thereby increases MRR [35,36]. The effect of T on and current predicts the higher value of MRR when the current is in between 3.2 to 4 A and for any value of T on (between 35 µs to 55 µs) Figure 7.…”

Section: Resultsmentioning

confidence: 99%

Multi-Response Optimization of WEDM Process Parameters for Machining of Superelastic Nitinol Shape-Memory Alloy Using a Heat-Transfer Search Algorithm

et al. 2019

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Nitinol, a shape-memory alloy (SMA), is gaining popularity for use in various applications. Machining of these SMAs poses a challenge during conventional machining. Henceforth, in the current study, the wire-electric discharge process has been attempted to machine nickel-titanium (Ni55.8Ti) super-elastic SMA. Furthermore, to render the process viable for industry, a systematic approach comprising response surface methodology (RSM) and a heat-transfer search (HTS) algorithm has been strategized for optimization of process parameters. Pulse-on time, pulse-off time and current were considered as input process parameters, whereas material removal rate (MRR), surface roughness, and micro-hardness were considered as output responses. Residual plots were generated to check the robustness of analysis of variance (ANOVA) results and generated mathematical models. A multi-objective HTS algorithm was executed for generating 2-D and 3-D Pareto optimal points indicating the non-dominant feasible solutions. The proposed combined approach proved to be highly effective in predicting and optimizing the wire electrical discharge machining (WEDM) process parameters. Validation trials were carried out and the error between measured and predicted values was negligible. To ensure the existence of a shape-memory effect even after machining, a differential scanning calorimetry (DSC) test was carried out. The optimized parameters were found to machine the alloy appropriately with the intact shape memory effect.

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“…Ram Prasad et al [27] also reported pulse on time and peak current as the most significant process variables affecting SR in WEDM of Ti-6Al-4V which is consistent with present ANOVA result. The highest impact of pulse on time on SR is also observed by Tonday and Tigga [28].…”

Section: Anova Of Surface Roughnessmentioning

confidence: 88%

Experimental investigation and parametric optimization for minimizing surface roughness during WEDM of Ti6Al4V alloy using modified TLBO algorithm

Devarasiddappa

Chandrasekaran

Arunachalam

2020

J Braz. Soc. Mech. Sci. Eng.

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Wire-cut electrical discharge machining (WEDM) is a widely used non-contact machining process used to cut difficultto-machine materials such as titanium, nickel and inconel alloys. WEDM is famous for producing components in diverse engineering applications, including automotive, marine, space, medical sectors with the highest accuracy and consistency. In this paper, experimental investigation on surface roughness (SR) of Ti6Al4V alloy employing WEDM process is presented using Taguchi L 16 experimental plan by varying four process variables, viz., pulse on time (T on), pulse off time (T off), current (I) and wire speed (WS) at four different levels. The novelty of the present work is minimization of surface roughness (SR) in WEDM of Ti6Al4V alloy employing reusable wire technology during experimental work and optimizes the problem with modified teaching-learning-based optimization (M-TLBO) algorithm. A novel technique for fitness curve fitting is also illustrated to obtain global optima for minimization of SR. Results showed that SR decreased by 2.65% at optimal parameter setting T on = 13 µs, T off = 10 µs, I = 1 A and WS = 850 rpm and global optima is obtained as 3.749 µm. Pulse on time (44.06%) and current (28.69%) are recognized as the most dominant process variables affecting SR followed by pulse off time (15.80%) and wire speed (7.47%). Surface morphology study of machined Ti alloy using SEM images showed that smoother surface is obtained at lower settings of pulse on time and current. The proposed M-TLBO algorithm is found to be highly accurate and consistent during several runs conducted with mean fitness value and standard deviation recorded as 3.751 µm and 0.006417, respectively.

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Analysis of Effects of Cutting Parameters of Wire Electrical Discharge Machining on Material Removal Rate and Surface Integrity

Cited by 13 publications

References 8 publications

Investigation on Surface Roughness and MRR in WEDM of Titanium Grade 7 (Ti-0.15Pd) Alloy using Statistical Techniques

Investigation on Surface Roughness and MRR in WEDM of Titanium Grade 7 (Ti-0.15Pd) Alloy using Statistical Techniques

Multi-Response Optimization of WEDM Process Parameters for Machining of Superelastic Nitinol Shape-Memory Alloy Using a Heat-Transfer Search Algorithm

Experimental investigation and parametric optimization for minimizing surface roughness during WEDM of Ti6Al4V alloy using modified TLBO algorithm

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