Investigation of the machining parameters and integrity of the work and wire surfaces after finish cut WEDM of commercially pure titanium

Chalisgaonkar, Rupesh; Kumar, Jatinder

doi:10.1007/s40430-015-0335-3

Cited by 34 publications

(18 citation statements)

References 25 publications

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“…Based on the reported literature, it is inferred that discharge energy influences both material removal rate and surface roughness in the wire EDM process [14,18].…”

Section: Materials Removal Ratementioning

confidence: 99%

“…The selection of appropriate machining parameters for the WEDM process is purely based on the analysis relating the various process parameters to different performance measures namely the MRR, surface finish, kerf width, tool wear, etc. 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.…”

Section: Introductionmentioning

confidence: 99%

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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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“…Based on the reported literature, it is inferred that discharge energy influences both material removal rate and surface roughness in the wire EDM process [14,18].…”

Section: Materials Removal Ratementioning

confidence: 99%

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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“…Additionally, the vaporization of zinc coating helps to maintain lower temperature of wire core, which permits use of more intensive pulse power and results in increased cutting speed. The enhancement in the machining speed contributed to the higher surface roughness observed during the trim cut operation with zinc coated wire [10] It is observed that with zinc coated wire material removal rate is higher as compared to plain brass wire. Direct dependence of the cutting efficiency upon both melting temperature and work function, was revealed, the cutting speed was observed to increase with the increase of the melting temperature.…”

Section: Fig 3 Main Effect Plot For S/n For Surface Finishmentioning

confidence: 92%

“…The microstructure analysis of the work surface indicated that zinc coated wire produced overlapping thick layer of debris while uncoated wire produced more number of craters under similar higher pulse discharge energy conditions. [10] Arvind Kumar Yadav et al [11] made a comparative study of zinc coated and bare electrode in EDM. It was concluded that coated tool electrode have significant effect on the material removal rate, tool wear and surface finish.…”

Section: Introductionmentioning

confidence: 99%

Effect of Electrode Coatings in Wire Electrical Discharge Machining of Inconel-718

Dhale¹,

Kulkarni²

2016

IOSR

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Wire electro-discharge machining (WEDM) has developed as extensively recognized non-traditional machining process for difficult-to-cut materials. In this paper, the behavior of Inconel-718, has been studied by varying electrode coating using WEDM, with respect to performance measures such as MRR and surface finish. All experiments were performed on Electronica Ultra cut wire EDM. The experiments were conducted by varying pulse on time, pulse off time, wire feed, wire tension, dielectric flush pressure. The experimental results confirm that, with coated wire, material removal rate and surface finish is better.

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“…These coating materials are required for improving the cutting efficiency because the existing wires do not fulfill all the requirements. R. Chalisgaonkar and J. Kumar 3 explored the characteristics of pure titanium during rough cut operation, and after the finish cut operation, they revealed the microstructure analysis of zinccoated and in the uncoated wires the erosion during the rough cut operation was found to be more than the finish cut. B. Sivaraman et al 4 stated that in the WEDM process the Taguchi method is most ideal and suitable, it simplifies the optimisation of multiple performance characteristics by avoiding complicated mathematical computations.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation for the optimization of the WEDM process parameters to obtain the minimum surface roughness of the Al 7075 aluminium alloy employed with a zinc-coated wire using RSM and GA

Shanthi¹,

Raman²,

Ramasamy³

2019

Mater. Tehnol.

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Wire Electrical Discharge Machining (WEDM) is widely used for machining conductive materials of intricate, complex and challenging shapes in the field of aerospace, die and mould making, automobile industries and the medical field. Proper selection of the WEDM process parameters can give good responses. Out of the various process responses, to achieve the minimum surface roughness is very difficult, due to arcing by the electrical discharge. The present investigation has been made to optimize the process parameters of WEDM during machining the Al 7075 aluminium alloy with zinc-coated copper wire using the Response Surface Methodology (RSM). Four input process parameters of WEDM, i.e., Pulse On Time, Pulse Off Time, Wire Feed and Wire Tension, were chosen as the process variables to study the process performance and to obtain the minimum surface roughness. An analysis of variance (ANOVA) was carried out to study the effect of the process parameters on the surface roughness and a mathematical model was developed. The model has been verified and checked for adequacy. The best fit surface roughness (Ra) value predicted is 1.048 μm for a Pulse On (TON) value of 120 μsec, a Pulse Off (TOFF) value of 58 μsec, a Wire Feed (WF) of 3 m/min and a Wire Tension (WT) value of 9 gm. Furthermore, it is observed that with an increase in the pulse-on time the Surface Roughness also increases, and an increase in the pulse-off time and the wire tension, the Surface Roughness decreases. Wire Feed does not influence much on the Surface Roughness.

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Investigation of the machining parameters and integrity of the work and wire surfaces after finish cut WEDM of commercially pure titanium

Cited by 34 publications

References 25 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

Effect of Electrode Coatings in Wire Electrical Discharge Machining of Inconel-718

Experimental investigation for the optimization of the WEDM process parameters to obtain the minimum surface roughness of the Al 7075 aluminium alloy employed with a zinc-coated wire using RSM and GA

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