Investigate WEDM Process Parameters on Wire Wear Ratio, Material Removal Rate and Surface Roughness of Steel 1012 AISI

Shather, Saad Kariem; Mohammed, Mohammed T.

doi:10.30684/etj.36.3a.3

Cited by 7 publications

(6 citation statements)

References 1 publication

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“…The wire wear ratio (WWR) has been measured from the loss of wire materials during the cutting process concerning the time and initial weight of wire is to be taken before machining process [17] (Eq. (3)).…”

Section: Methodsmentioning

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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Section: Methodsmentioning

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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“…Weight loss of molybdenum wire electrode was determined as the difference between the weight of wire electrode from the reel before trial to the weight of wire after conducting each trial. The wire wear ratio can be determined by equation [35] (1).…”

Section: Experimentation Of Ndwedm and Cryogenic Cooled Ndwedmmentioning

confidence: 99%

“…While increasing pulse width, the WWR is getting maximized by a [38]. It was increased by increasing air pressure (from 3 bar to 5 bar) and flow rate (from 10 ml min −1 to 20 ml min −1 ) due to an increase in the uniform spark intensity, sufficient cooling, and flushing efficiency [13,35,39,40]. It causes to increase in the heat transfer rate and material deposition on the machined surfaces.…”

Section: Process Parameters Influence On Wire Wear Ratio (Wwr)mentioning

confidence: 99%

Experimental comparison of near-dry and cryogenically cooled near-dry machining in wire-cut electrical discharge machining processes

Myilsamy¹,

Boopathi²

2021

Surf. Topogr.: Metrol. Prop.

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In this research, the wire wear ratio (WWR), material removal rate (MRR) and surface roughness (SR) of cryogenic cooled near dry wire-cut electrical discharge machining (NDWEDM) is compared with the existing NDWEDM process. Cryogenic cooled and un-cooled molybdenum wires and Inconel 718 alloy have been used as the electrodes and work-material respectively. The novel experimental setup has been fabricated to mix the minimum amount of water with pressurized air as a dielectric fluid. The control variables such as Air pressure (P), Flow rate (F), Current (I), Pulse width (PW), and Pulse Interval (PI) are measured to conduct both NDWEDM experiments using the L27 Taguchi method. It was revealed from systematic studies that WWR of cryogenic cooled NDWEDM is reduced to 29%, MRR is increased to 15.6% and SR is reduced to 7.23% than existing NDWEDM due to an increase in electric conductivity and effective spark strengths by cryogenic cooled wire. It was revealed from SEM images that the macro crater in the existing NDWEDM and the micro crater of wire in the cryogenic NDWEDM process have been studied.

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“…Wire Electrical Discharge Machining (WEDM) is one of the important non-traditional machining processes among the others, it has become efficient solution to create complex contour features like intricate shape and profiles on difficult-to-machine materials [3]. The material removal mechanism of WEDM is involving the erosion effect produced by the electrical discharges, like electrical discharge machining (EDM) process.…”

Section: Introductionmentioning

confidence: 99%

Effects of Wire-EDM Machining Variables on Surface Roughness of D2 Steel Material

Rudrapati

Rathod

2019

MSF

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Newly developed D2 steel is widely used for various advanced engineering applications. Machining of D2 steel to obtain desired quality responses has immense importance for the effective utilization of these materials for advanced industrial applications like aerospace, marine, automobile, etc. Wire electrical discharge machining (WEDM) is used to machine difficult to machine materials and to produce sophisticated features with better dimensional accuracy. Obtaining the fine surface roughness in WEDM has highly depends on correct selection of process parameters. In the present work, experimental investigation was planned to study the effects of WEDM input parameters on surface roughness (Ra) of D2 steel. Experimental runs were conducted by using L16 orthogonal array of Taguchi method. The analysis of variance was employed to determine the influences of process parameters on Ra. Response surface methodology (RSM) and cuckoo search optimization (CSO) algorithm had been used to model and optimize the surface roughness. From the study, it was found that Ra value had improved as compared to initial experimental runs.

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Investigate WEDM Process Parameters on Wire Wear Ratio, Material Removal Rate and Surface Roughness of Steel 1012 AISI

Cited by 7 publications

References 1 publication

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 comparison of near-dry and cryogenically cooled near-dry machining in wire-cut electrical discharge machining processes

Effects of Wire-EDM Machining Variables on Surface Roughness of D2 Steel Material

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