Analysis of the machinability of different types of sintered carbides with WEDM in both water and oil baths

Mouralová, Kateřina; Beneš, Libor; Prokeš, Tomáš; Zahradníček, Radim; Fries, Jiří; Plichta, Tomas

doi:10.1007/s00170-023-10913-4

Cited by 7 publications

(2 citation statements)

References 29 publications

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“…However, classical methods based on gradient are not always suitable for modeling because it is sometimes difficult to obtain relevant gradient data, thereby making it impossible to obtain objective functions [55][56][57]. Stochastic and metaheuristic approaches, relative to classical approaches, provide an advantage in that no additional data are required for their introduction [58][59][60][61]. In addition, these approaches introduce a random step size within the calculation-based numerical iteration.…”

Section: Analysis Of Aspects Of Multiparametric Optimization Of the O...mentioning

confidence: 99%

Prediction and Multiparametric Optimization of the Machined Surface Quality of Tool Steels in Precise Wire Electrical Discharge Machining

Straka,

Čorný

2024

Machines

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This article describes a proposed procedure for multiparametric optimization of the quality of machined surfaces, including mathematical models that can predict the high quality of a precisely machined surface and, at the same time, the high productivity of the process in WEDM of tool steels. The experimental research was carried out using the full DoE factorial design method, which has four technological parameters. The measured output qualitative parameter Surface Roughness (SR) and the output quantitative parameter Material Removal Rate (MRR) were evaluated using the Grey Relational Analysis (GRA) and Analysis of Variance (ANOVA) methods. Multiple Regression Models (MRM) were developed to represent the multiple responses of the investigated tool steels using a regression tool set. The results of the multiparametric optimization revealed a correlation between the input variable parameters of the electrical discharge process, while the favorable results of the observed output-dependent parameters SR and MRR were coupled to the parameters of low peak current I, low value of pulse on-time duration ton, low voltage of discharge U, and high value of pulse off-time duration toff. Based on the multiparametric optimization, key results were obtained that demonstrated the mutual dependence of the observed output process parameters. An optimum SR value of 1.50 μm was obtained with L8-level settings for the input variable parameters I, ton, U, and toff (2 A, 32 μs, 90 V, and 20 μs, respectively) and an MRR value of 12.50 mm3·min−1 was achieved.

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Section: Analysis Of Aspects Of Multiparametric Optimization Of the O...mentioning

confidence: 99%

Prediction and Multiparametric Optimization of the Machined Surface Quality of Tool Steels in Precise Wire Electrical Discharge Machining

Straka,

Čorný

2024

Machines

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“…The wire tool electrode is also important in the micro-WEDM process because it affects the cutting speed, dimensional accuracy, and the quality of the machined surface [ 11 ]. Micro-WEDM uses wire electrodes with a diameter of 0.05–0.1 mm made of Ms, Cu, Fe, Mo, W, and other materials [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

Simulation and Optimization of Surface Roughness and Process Performance during Machining of HSS by Micro-WEDM Technology

Straka,

Čorný

2024

Micromachines

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When machining high-speed steels (HSS) with micro-wire electrical discharge machining (micro-WEDM), high surface quality is achieved as standard. The value of the roughness parameter Ra is less than 0.2 μm. However, the problem is the performance of the electroerosion process (MRR), which is low. This problem is related to the mechanical and physical properties of the HSS in combination with the setting of the main technological parameters (MTP). The proposed solution to eliminate this problem relies on the selection of proper procedures for the determination of optimization criteria in relation to Ra and MTP, with the inclusion of properties of the machined material. The solution consisted in the identification of four significant physical (ρ, κ) and mechanical (Rm, HRC) indicators of HSS properties, on the basis of which a suitable combination of the process output parameters Ra and MRR can be determined through established mathematical regression models using simulation and optimization. In the next step, the proper values of the MTP output process parameter settings, which correspond to the optimized output parameters Ra and MRR during machining of HSS by micro-WEDM technology, were then obtained by the same approach.

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Fundamental study on dielectric oil viscosity for high-performance wire EDM

Liu,

Okada,

Kitamura

2024

Int J Adv Manuf Technol

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Dielectric oil has been recently used in wire electrical discharge machining (wire EDM) for achieving high-precision machining. However, the influence of dielectric oil properties on wire EDM characteristics has not been clarified sufficiently. This study fundamentally investigated the influence of dielectric oil viscosity on wire EDM characteristics. In this study, three types of dielectric oil differing only in viscosity were prepared and examined. Linear cutting experiment results showed that the removal rate and the machined surface roughness increase with dielectric oil viscosity. Then, the influence of viscosity on crater removal volume was investigated to discuss the cause of the change in removal rate, and it was found that crater removal volume increases with the viscosity. Furthermore, CFD (computational fluid dynamics) analysis results and discharge observation results showed that the debris exclusion becomes worse in higher viscosity oil, and the discharge concentration occurs frequently, resulting in the deterioration in machined surface roughness. Next, the difference in machining accuracy with dielectric oil viscosity was investigated. It was found that the corner shape accuracy deteriorates with the increase of viscosity while the machined surface waviness and straightness improve slightly. Structural analysis results showed that wire deflection increases with viscosity, resulting in the deterioration in corner shape accuracy. On the other hand, high-speed observation of wire vibration was carried out, and it was found that the wire vibration decreases in the case of higher viscosity, which leads to the improvement in machined surface waviness and straightness.

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Analysis of the machinability of different types of sintered carbides with WEDM in both water and oil baths

Cited by 7 publications

References 29 publications

Prediction and Multiparametric Optimization of the Machined Surface Quality of Tool Steels in Precise Wire Electrical Discharge Machining

Prediction and Multiparametric Optimization of the Machined Surface Quality of Tool Steels in Precise Wire Electrical Discharge Machining

Simulation and Optimization of Surface Roughness and Process Performance during Machining of HSS by Micro-WEDM Technology

Fundamental study on dielectric oil viscosity for high-performance wire EDM

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