Modeling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation

Sarkar, Soham; Sekh, Mukandar; Mitra, S.; Bhattacharyya, B.

doi:10.1016/j.jmatprotec.2007.11.194

Cited by 138 publications

(52 citation statements)

References 24 publications

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“…This graph also shows that the SR may be improved significantly using trim cutting operation irrespective of high DE in rough cut operation. In trim cutting operation, a very thin layer of surface material is removed at appropriate wire offset value and thereby surface irregularities (peaks) are minimized to improve the SR. Wire offset (WO) has a significant impact on SR for trim cut (Jangra, 2015;Sarkar et al, 2008). By decreasing WO value beyond 125µm (radius of wire), the area of contact between wire electrode and work surface increases.…”

Section: Effect On Surface Roughness (Sr)mentioning

confidence: 99%

See 1 more Smart Citation

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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Section: Effect On Surface Roughness (Sr)mentioning

confidence: 99%

“…In trim cut, wire electrode traces back the rough cut path with certain value of wire offset (WO) to remove a very small layer of work surface (Jangra, 2015;Sarkar et al, 2008) as shown in Fig. 1.…”

Section: Introductionmentioning

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

View full text Add to dashboard Cite

show abstract

“…Therefore, one or more trim cuts (Sarkar et al, 2005(Sarkar et al, , 2008 are required after rough cut, to minimize the surface defects and geometrical inaccuracies. But sometimes, improper parameters setting during rough cutting operation may deteriorate the work surface very severely, which may not be improved considerably after one or more trim cuts (Juhr et al, 2004).…”

Section: Fig 1 Representation Of Wedm Processmentioning

confidence: 99%

“…But in case of small cavities having complex geometries and tapers, trim cutting operation on WEDM is best alternative. In trim cutting operation on WEDM, wire electrode traces back the same path with certain wire offset value and low discharge energy with respect to first or rough cut (Sarkar et al, 2008). In present work, maximum three number of trim cuts were performed with different wire offset values and constant parameters of Ip: 90amp.…”

Section: Removal Of Surface Projectionsmentioning

confidence: 99%

Study of unmachined area in intricate machining after rough cut in WEDM

Jangra¹

2012

IJIEC

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Wire electrical discharge machining (WEDM) is well known process for generating intricate and complex profiles in hard metal matrix composites. But damaged surface layer with poor surface integrity is a major disadvantage of WEDM. Beside poor damaged surface layer, after rough/first cut in WEDM, some surface area remains unmachined on work surface during intricate machining such as in die cutting. This paper presents a study on unmachined surface area named as surface projection, in die cutting after rough cut in WEDM. Using scanning electron microscope images, length of unmachined surface projections have been determined. In order to minimize these surface projections from small cavities having complex geometries, trim cutting operation is the best alternative. Results show that using more than one trim cut with appropriate wire offset value, surface projections can be minimized, successfully.

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“…RoC helps to predict accurate wire offset for precise dimensional tolerance. Neglecting the wire lag compensation for straight cutting, wire offset is given by the sum of wire radius and RoC (Sarkar et al, 2008). RoC was measured using optimal microscope.…”

Section: Performance Characteristicsmentioning

confidence: 99%

Modelling and experimental investigation of process parameters in WEDM of WC-5.3 % Co using response surface methodology

Jangra

Grover

2012

Mech. Sci.

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Abstract. Tungsten carbide-cobalt (WC-Co) composite is a difficult-to-machine material owing to its excellent strength and hardness at elevated temperature. Wire electrical discharge machining (WEDM) is a best alternative for machining of WC-Co composite into intricate and complex shapes. Efficient machining of WC-Co composite on WEDM is a challenging task since it involves large numbers of parameters. Therefore, in present work, experimental investigation has been carried out to determine the influence of important WEDM parameters on machining performance of WC-Co composite. Response surface methodology, which is a collection of mathematical and experimental techniques, was utilised to obtain the experimental data. Using face-centered central composite design, experiments were conducted to investigate and correlate the four input parameters: pulse-on time, pulse-off time, servo voltage and wire feed for three output performance characteristics -cutting speed (CS), surface roughness (SR) and radial overcut (RoC). Using analysis of variance on experimental data, quadratic vs. two-factor interaction (2FI) models have been suggested for CS and RoC while two-factor interaction (2FI) has been proposed for SR. Using these mathematical models, optimal parameters can be determined easily for desired performance characteristics, and hence a trade-off can be made among different performance characteristics.

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Modeling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation

Cited by 138 publications

References 24 publications

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

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

Study of unmachined area in intricate machining after rough cut in WEDM

Modelling and experimental investigation of process parameters in WEDM of WC-5.3 % Co using response surface methodology

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