Material removal rate and surface roughness study on Near-dry wire electrical discharge Machining process

Boopathi, S.; Myilsamy, Sureshkumar

doi:10.1016/j.matpr.2021.02.267

Cited by 34 publications

(13 citation statements)

References 15 publications

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“…It was revealed that pulse-width is a very significant contribution to MRR and pulse interval has more contribution on Ra. The plots show that voltage, pulse width, and flow rate have a more momentous consequence on MRR and Ra than pulse-interval [8,9,[12][13][14]. The validation tests are used to authorize the predicted outcomes from the Taguchi Method.…”

Section: Results Analysismentioning

confidence: 99%

“…It was observed from comparative studies, the oxygen-mist near-dry WEDM process has better performance than the air-mist near-dry process [7]. The Monel metal, EN-31 die steel, ANSI-D3 steel, and Tungsten carbide (WC) as work materials and air/ gas-mist as dielectric fluids had been investigated in near-dry WEDM processes [8,9]. It was also tried to investigate the near-dry WEDM process to cut various alloy materials by few researchers.…”

Section: Introductionmentioning

confidence: 99%

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Experimental Investigations on Eco-Friendly Helium-Mist Near-Dry Wire-Cut EDM of M2-HSS Material

Velmurugan¹,

Yuvaraj²,

Raguraman³

et al. 2021

Recent Advancements in Geotechnical Engineering

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Abstract. In this paper, helium-assisted near-dry wire-cut electrical discharge machining (NDWEDM) method molybdenum wire has been used to reduce the environmental impact and to cut M2-HSS material. The pressurized non-reacting helium gas mixed with a small amount of water (Helium-mist) is used as the dielectric fluid to accomplish adequate cooling and flush-out debris. The new experimental setup has been developed to conduct the near-dry WEDM tests using the L9 orthogonal array of the Taguchi technique. The input parameters such as voltage (V), pulse-width (PW), pulse-interval (PI), and flow rate (F) of mixing water and output variables are the material removal rate (MRR) and surface roughness (Ra). It was observed that MRR and Ra are amplified by the rise in voltage and pulse-width, and flow rate conversely, the pulse interval minimizes the responses. The percentage of contribution of pulse width, voltage, pulse interval and flow rate are 24.06%, 32.98%, 12.75% and 30.21% on MRR and 20.94%, 22.22%, 47.86% and 8.97% on Ra respectively. Finally, the confirmation trials have been accomplished to validate the foreseen best parameter sets on optimal responses.

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Section: Results Analysismentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental Investigations on Eco-Friendly Helium-Mist Near-Dry Wire-Cut EDM of M2-HSS Material

Velmurugan¹,

Yuvaraj²,

Raguraman³

et al. 2021

Recent Advancements in Geotechnical Engineering

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show abstract

“…It is also significantly enhanced by increasing the flushing efficiency and due to the quick disposal of debris from the cutting zone [63]. For the plot the response surface plot between C and PI (Figure 6(c)), C× PI interaction terms are included even if it is insignificant [10,64]. The MRR is increased by reducing pulse interval due to an increase in spark pause time.…”

Section: 1response Surface Analysis Using Box-behnken Methodsmentioning

confidence: 99%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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In this research, the mixing of compressed air with the minimum quantity of water is used as a dielectric medium and the cryogenically cooled molybdenum wire is used as a tool in wire-cut electrical discharge machining (WEDM) to encourage the eco-friendly production, called cryogenically cooled near-dry WEDM process. The nitrogen gas-cooled wire tool is utilized to cut the Inconel 718 alloy workpiece to prevent wire breakage and maintain enough electrical conductivity. The preliminary experiments were conducted to compare wet, dry, near-dry, and cryogenically cooled near-dry WEDM processes. It was revealed that cryogenic cooled near-dry WEDM is better performance than dry, near-dry WEDM except for the wet process. The systematic experiments of eco-friendly cryogenically cooled near-dry WEDM have been conducted to analyse the effect of input factors like spark current, pulse-width, pulse-interval, and mixing water flow rate on material removal rate (MRR) and surface roughness (SR) using Box–Behnken method. The fitted models and response surface graphs were developed to analyse the influences of input factors on each response parameter. It was concluded that MRR and SR of cryogenically cooled near-dry WEDM are increased by maximizing spark current, pulse-width, and flow rate, conversely, both responses were decreased by increasing pulse-interval. The technique for order of preference by similarity to ideal solution (TOPSIS) technique has been applied to predict the best combination of input factors for satisfying the optimal values of both responses.

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“…<Insert Figure 3 about here> It was indicated from Taguchi analysis (Figure 3) that the moderate air pressure (5 bar) improves the MRR due to efficient flushing and sufficient cooling effect in the near-dry WEDM process (Boopathi and Sivakumar 2012;Boopathi and Myilsamy 2021). At the low air pressure (3 bar), the metal debris is reduced due to insufficient spark in the plasma zone.…”

Section: Analysis Of Mrrmentioning

confidence: 99%

Sustainable Eco-friendly Wire-cut Electrical Discharge Machining: Gas Emission Analysis

Boopathi¹

2021

Preprint

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Wire-cut electrical discharge machining (WEDM) is the highly essential unconventional electro-thermal machining process to cut the contour profile of hard materials in modern production industries. The various environmental impacting wastes (by evaporating and reacting hydro-carbon dielectric fluid) are produced during the WEDM process and these are harmful to the machine operators. These wastes are minimized by a near-dry WEDM process wherein the pressurized air mixed with a small amount of water is used as a dielectric substance. In this research, influences, and contributions of machining parameters such as air pressure, mixing water flow rate, spark current and pulse width on gas emission concentration (GEC), materials removal rate (MRR), and relative emission rate (RER) of sustainable near-dry WEDM process have been optimized by Taguchi analysis. RER is investigated to analyze the effects of machining factors on gas emission and machining rate combinedly. It was revealed that the maximum air pressure and flow rate of mixing water have significantly been promoting the sustainable near-dry WEDM process.

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Material removal rate and surface roughness study on Near-dry wire electrical discharge Machining process

Cited by 34 publications

References 15 publications

Experimental Investigations on Eco-Friendly Helium-Mist Near-Dry Wire-Cut EDM of M2-HSS Material

Experimental Investigations on Eco-Friendly Helium-Mist Near-Dry Wire-Cut EDM of M2-HSS Material

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Sustainable Eco-friendly Wire-cut Electrical Discharge Machining: Gas Emission Analysis

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