Microstructure Analysis and Material Transformation of Pure Titanium and Tool Wear Surface After Wire Electric Discharge Machining Process

Kumar, Anish; Kumar, Vijay; Kumar, Jatinder

doi:10.1080/10910344.2014.863632

Cited by 43 publications

(18 citation statements)

References 37 publications

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“…Specifically, less significant literature has been found by the authors relating to optimization of surface integrity analysis in terms of surface crack density and recast layer thickness after processing with WEDM using pure titanium. A previous study reported by the same authors (Kumar et al, 2013a(Kumar et al, , 2013b(Kumar et al, , 2013cKumar et al, 2014aKumar et al, , 2014b has been shown that the most significant parameters are pulse on time, pulse off time and peak current for the surface integrity of pure titanium. Now, the novelty of current research further extended to develop the mathematical models in terms of surface crack density and recast layer thickness through response surface methodology.…”

Section: Introductionmentioning

confidence: 92%

Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

Kumar

2016

Machining Science and Technology

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In this work, quantitative assessment of surface damage in terms of parameters like surface crack density and recast layer thickness in wire electrical discharge machining (WEDM) process has been undertaken. The effect of processing conditions on crack formation is studied using scanning electron microscope. Surface crack density and recast layer thickness analysis in terms of machining parameters such as pulse on time, pulse off time, peak current, spark gap voltage significantly deteriorate the microstructure of machined samples, which produces the deeper, wider overlapping craters, pock marks, globules of debris and micro cracks. The microstructure analysis of WEDM surface was based upon the theory of electrical discharge phase and metallurgical physics. It is found that the pulse on time, pulse off time and peak current are the most dominating parameters for both surface crack density and recast layer thickness.

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Section: Introductionmentioning

confidence: 92%

Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

Kumar

2016

Machining Science and Technology

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“…Zhang et al (2014) developed a macroscopic mechanical model of wire electrode deflection considering temperature increment in MS WEDM Process. Kumar et al (2014) studied the microstructural analysis and tool wear surface of pure titanium in wire Electric discharge machining process. They found rupturing and wear in the wire due to high values of spark frequency and peak current.…”

Section: Literature Reviewmentioning

confidence: 99%

A multi objective optimization of gear cutting in WEDM of Inconel 718 using TOPSIS method

Mohapatra¹,

Sahoo²

2018

10.5267/j.dsl

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The present paper deals with the experimental analysis and multi objective optimization of gear cutting process of Inconel 718 using WEDM. The objective of the present work is to optimize the parameters in order to maximize the material removal rate and minimize the kerf in a gear cutting process to get the optimum value. The MRR and kerf play a major role in optimizing the parameters in WEDM process. The experiment is carried out in the wire EDM machine using brass wire as the electrode, Inconel 718 as the work-piece material and distilled water as the dielectric. The design array is created by using Design of Experiment in a Taguchi L16 orthogonal array repeated once. The gear has a base diameter of 20 mm, addendum diameter of 22.5 mm and a pressure angle of 20º with 16 numbers of teeth. The machining operation is carried out by taking 3 input parameters at 4 different levels each. The output parameters such as Material Removal rate and Kerf width were obtained and optimized using TOPSIS method to know the optimum setting. Microstructural analysis of both material and wire were studied to know the various defects during the machining operation. Various plots were obtained to know the effects of the process parameters in WEDM. A regression model was also obtained to validate the statistical model values with the experimental. ANOVA table and Response table were carried out to know the significant parameters and rank respectively in the Wire EDM process. Surface roughness, Addendum and Tooth width of gears were also found out at the optimum settings. The optimum setting of the gear obtained can be used to produce high quality gears and can also be applied for future findings.

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“…on machining performance like cutting speed (CS), metal removal rate (MRR), surface roughness (SR), geometrical accuracy, recast layer etc. in processing of different work materials ranging from simple alloy steel, aluminium MMC high strength-heat resisting alloys and composite materials (Bhuyan & Yadava, 2014;Bobbili et al, 2014;Delgado et al, 2011;Gupta & Jain, 2014;Hascalyk et al, 2004;Hewidy et al, 2005;Huang et al, 1999;Jangra & Grover, 2012;Kumar et al, 2013;Kumar et al, 2014;Prohaszka et al, 1997;Shandilya et al, 2013;Yu et al, 2011). The majority of the research works conducted on WEDM deal with rough cut and very limited research works are conducted for trim cutting operation (Jangra, 2012).…”

Section: Literature and Motivation For Present Workmentioning

confidence: 99%

An experimental study on trim cutting operation using metal powder mixed dielectric in WEDM of Nimonic-90

Kumar¹,

Jangra²,

Kumar³

2016

10.5267/j.ijiec

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This paper presents an experimental study on rough cut, trim cut using distilled water as a dielectric fluid and Al & Si metal powders in dielectric fluid for WEDM of Nimonic-90. First, the influence of discharge energy (DE) in rough cut is evaluated for machining rate (MR) and surface roughness (SR) and compared with trim cut without any metal powder additives in dielectric fluid. The effect of Al and Si metal powders (varying concentration of 1g/L, 2g/L and 3g/L) in dielectric fluid is studied separately and comparison is also made for MR, SR, recast layer and micro hardness of machined Nimonic-90. From the results it is observed that using trim cut, a fine and uniform surface texture is obtained irrespective of the high discharge energy of rough cut. Al and Si powders additives show a significant reduction in MR for trim cutting operation whereas a remarkable modification is obtained in surface textures after trim cut using metals powder mixed dielectric. SR improves with a concentration of 1g/L and shows a little increase with high concentration of both metals powder. Using metals powder in dielectric fluid, the recast layer becomes smooth and denser and thus, micro hardness increases.

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Microstructure Analysis and Material Transformation of Pure Titanium and Tool Wear Surface After Wire Electric Discharge Machining Process

Cited by 43 publications

References 37 publications

Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

Surface crack density and recast layer thickness analysis in WEDM process through response surface methodology

A multi objective optimization of gear cutting in WEDM of Inconel 718 using TOPSIS method

An experimental study on trim cutting operation using metal powder mixed dielectric in WEDM of Nimonic-90

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