Experimental and numerical study of angular error in wire-EDM taper-cutting

Sánchez, J.A.; Plaza, Soraya; Ortega, Naiara; Marcos, M.; Albizuri, Joseba

doi:10.1016/j.ijmachtools.2008.04.011

Cited by 48 publications

(24 citation statements)

References 13 publications

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“…Optimization techniques such as design of experiments [9], response surface methodology [10][11][12], fuzzy control system [13][14][15][16][17], genetic algorithm [18] and grey relational analysis [19] are the inevitable tool in achieving optimum process parameters of the wire EDM process. A similar kind of evaluation has also been performed by many researchers on various materials like Inconel [20,21], AISI D2 [22,23], titanium and titanium super alloys [24][25][26][27], etc. Based on the evaluation of those research papers on wire EDM, it has been seen that different attempts are made on the investigations of predicting the effect of process parameters on various conductive materials for achieving maximum material removal rate (MRR), minimum surface roughness (Ra) and wire wear ratio (WWR) on wire EDM and they were found useful.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS

Rajmohan¹,

Kumar²

2016

Int J Adv Manuf Technol

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Micro-wire-cut electrode discharge machining (EDM) is an emerging manufacturing process in the field of micro-manufacturing to fabricate the complex profiles of micro-components. It is a complex process involving various process parameters such as pulse on time, pulse off time, wire speed, wire tension and current. In addition to micro-fabrication, this process can also be extended in the field of tool design and developments such as dies, moulds, precision manufacturing, contour cutting, etc., where complex shapes need to be generated with high-grade dimensional accuracy and surface finish. In this research work, an attempt is made to investigate the effect of process parameters on the output variables such as material removal rate (MRR), surface finish and the cutting width (kerf) of wire-cut EDM for duplex stainless steel (DSS). Scanning electron microscopy (SEM) has been used to capture the images of the kerf width, and the measurements are taken with the help of the welding expert system and software. An optimization technique (Taguchi method) has been employed to identify the optimum parameters of the micro-wire-cut EDM process for cutting 2205 grade duplex stainless steel. The effect of each control parameter on the performance measure is studied individually using the plots of signal to noise ratio.

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Section: Introductionmentioning

confidence: 99%

Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS

Rajmohan¹,

Kumar²

2016

Int J Adv Manuf Technol

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“…The back propagation neural network (BPNN) has been developed using the experimental data set as shown in Table 2. Out of 27 data, 75% of data (1)(2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(13)(14)(15)(16)(17)(18)(19)(20) are selected as training data and 25% of the data (21)(22)(23)(24)(25)(26)(27) have been used to test the performance of the selected neural network. To determine the number of neurons in the hidden layer, various back propagation neural network (BPNN) models have been chosen to achieve performance error equal to 0.001.…”

Section: Resultsmentioning

confidence: 99%

“…Plaza et al [3] have developed two models for the prediction of angular error in WEDM taper cutting and found that part thickness and taper angle are the most influencing variables. Sanchez et al [4] have presented a numerical and empirical approach for the prediction of angular error in WEDM taper cutting. A simulation approach is adopted by Sanchez et al [15] for analysis of angular error in wire-EDM taper cutting and verified by experimentation.…”

Section: Literature Reviewmentioning

confidence: 99%

“…During taper cutting operation in WEDM, the wire is subjected to deformation resulting deviations in the inclination angle of machined parts. As a result, the machined part loses its precision [3,4]. To achieve better output characteristics during taper cutting operation in WEDM process, simultaneous improvement on properties of wire electrodes and work piece materials seems to be vital.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of WEDM process parameters using deep cryo-treated Inconel 718 as work material

Nayak

Mahapatra

2016

Engineering Science and Technology, an International Journal

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A B S T R A C TThe present work proposes an experimental investigation and optimization of various process parameters during taper cutting of deep cryo-treated Inconel 718 in wire electrical discharge machining process. Taguchi's design of experiment is used to gather information regarding the process with less number of experimental runs considering six input parameters such as part thickness, taper angle, pulse duration, discharge current, wire speed and wire tension. Since traditional Taguchi method fails to optimize multiple performance characteristics, maximum deviation theory is applied to convert multiple performance characteristics into an equivalent single performance characteristic. Due to the complexity and nonlinearity involved in this process, good functional relationship with reasonable accuracy between performance characteristics and process parameters is difficult to obtain. To address this issue, the present study proposes artificial neural network (ANN) model to determine the relationship between input parameters and performance characteristics. Finally, the process model is optimized to obtain a best parametric combination by a new meta-heuristic approach known as bat algorithm. The results of the proposed algorithm show that the proposed method is an effective tool for simultaneous optimization of performance characteristics during taper cutting in WEDM process.

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“…The maximum angle that can be cut depends upon part thickness, but values about 30° can be easily achieved [2]. The main factors contributing to the geometrical inaccuracy of the WEDMed part are the various process forces acting on the wire caus-ing it to depart for the programmed path [3]. The problem of taper cutting was first time proposed by Kinoshita et al [4] who developed a linear model for wire deformation neglecting the forces produced during the process.…”

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of WEDM process parameters for taper cutting of AISI D2 tool steel

Kiran¹,

Nagaveni²,

Saraswathamma³

et al. 2018

IJET

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Wire electrical discharge machining (WEDM) process is one of the most popular method for the producing complex geometries in hard and wear resistant materials such as those used in tooling industry. This taper cutting involves in making of inclined surface, and it is particularly significant in the manufacturing of tooling that requires draft angles. In the present paper, experiments were conducted in order to find the effect of process parame-ters such as taper angle, geometrical thickness and servo voltage on response variables such as angular error and cutting speed on AISI D2 tool steel using statistical design of experiments. The experiments were planned using Central Composite design (CCD) which is part of Response Surface Methodology (RSM)involving three variables with five levels. Multi objective optimization was conducted for maximizing the Cutting speed and minimizing the angular error using genetic algorithm. The optimization procedure leads to creation of non-dominated optimal points which gave an insight regarding the optimal operating conditions of the process.

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Experimental and numerical study of angular error in wire-EDM taper-cutting

Cited by 48 publications

References 13 publications

Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS

Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS

Optimization of WEDM process parameters using deep cryo-treated Inconel 718 as work material

Multi-objective optimization of WEDM process parameters for taper cutting of AISI D2 tool steel

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