Mathematical Models for Machining Optimization of Ampcoloy 35 with Different Thicknesses Using WEDM to Improve the Surface Properties of Mold Parts

Abstract

Wire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box–Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5–160 mm thicknesses, both on the surface and in the subsurface layer.

A Concise Review on Materials for Injection Moulds and Their Conventional and Non-Conventional Machining Processes

“…Using TEM, a lamella analysis identified an elevated concentration of alloying elements in the recast layer. The analysis also revealed a shift in crystal orientation resulting from Wire EDM (WEDM) Mouralova et al [149] These authors developed mathematical models to optimize the machining process of AMPCOLOY ® 35 across a varying t, ranging from 5 mm to 160 mm in increments of 5 mm, employing WEDM to enhance the surface characteristics of mould parts. The Box-Behnken-type experiment design generated 448 samples.…”

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

“…In addition to these researchers, many others have attempted to investigate the effects of various input factors and their levels on the output performance parameters of the electrical discharge process. However, their research was often limited to selected types of materials in the context of machining performance parameters with subsequent modeling of the material properties of the workpiece and the tool electrode [ 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 ]. In their work, Mahapatra et al [ 51 ] evaluated relations and response control factors in WEDM such as MRR and cutting gap width by the Taguchi method.…”

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

“…To predict a better MRR, they developed a neural network model using MATLAB programming and its subsequent simulation. They then used genetic algorithms (GAs) to determine the optimal process parameters for the desired output value of the machining characteristics [24][25][26][27][28][29]. They demonstrated that the proposed neural network model enhanced with optimized machining parameters is effective in estimating the MRR.…”