Modeling of kerf width and surface roughness in wire cut electric discharge machining of Ti-6Al-4V

Rao, K. Venkata; Raju, Lam Ratna; Kumar, Chiluka Kiran

doi:10.1177/0954408920932369

Cited by 16 publications

(4 citation statements)

References 22 publications

(54 reference statements)

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“…However, to achieve this goal, obtain tolerances, and pay the desired level in form tools, they usually use the grinding process as the final process. The reason for this is the method's high speed and efficiency [10][11][12]. A form tool with a cutting edge has the reverse shape of the workpiece to be chipped.…”

Section: Production Techniques For Form Cutting Tools: a Comparative ...mentioning

confidence: 99%

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Alinaghizadeh,

Hadad,

Azarhoushang

2023

Micromachines

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In this research, a comparison between two methods of grinding and WEDM and the chip formation of each form tool was studied through a set of designs of experiments. A multi-functional form tool with different cutting-edge shapes was designed to compare different production methods, and a grinding machine and a five-axis wire-cutting machine were made. The form tools by the wire cutting method were made with three different machining states, rough, semi-finish, and finish. The results of the experimental test showed that the chip formation of the finished surface of the wire cut tool was close to the ground tools. Additionally, the tool life in wear generation was assessed, revealing that the tool generated through the wire-cutting method with three passes exhibited superior performance compared to alternative approaches. Furthermore, employing the wire-cutting technique with high surface finishing yielded optimal outcomes for producing form-cutting tools featuring complex profiles.

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Section: Production Techniques For Form Cutting Tools: a Comparative ...mentioning

confidence: 99%

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Alinaghizadeh,

Hadad,

Azarhoushang

2023

Micromachines

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“…Zhang et al reported that wire vibration affects not only the geometry profile of the components but also the recast layer thickness, material removal rate, surface morphology (Zhang et al, 2018). Rao et al reported that wire tension has an effect on kerf width and surface roughness, in addition, less surface roughness and smooth surface profiles can be obtained as a result of low current and high wire tension (Rao et al, 2020). Regarding this issue, Straka et al emphasized that the geometrical accuracy of the eroded surface has deteriorated significantly due to increasing flushing pressure (Straka et al, 2021).…”

Section: Test Parameters and Key Findingsmentioning

confidence: 99%

WEDM ile Kesilen Sleipner Soğuk İş Çeliğinin Kesim Kalitesine Pirinç ve Bakır Tel Kullanımının Etkileri

Ceritbinmez¹,

Kanca

2022

Journal of Materials and Mechatronics: A

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Wire electric discharge machining (WEDM) is widely used in dies, punches, aerospace and automotive sectors, since materials with high hardness, and temperature resistant, which are not possible to be cut with conventional machining methods, can be cut with high precision using the WEDM method. In this study, cutting speed (mm/min), material removal rate (mm3/min), wire consume (g), machining time (sec), finish measure (mm) and surface roughness (µm) changes as a result of cutting high hardness cold work tool steel using copper and brass wire in WEDM method were investigated. In addition, worn wire and workpiece residues on the machined surfaces were detected by SEM (Scanning Electron Microscope) and EDX (Energy Dispersive X-Ray) analyzes as well as topography and composition were examined. In the case of using copper wire instead of the brass wire, wire consumption and processing time decreased by 23.30 % and 66.29 %, respectively, while MRR increased by 50 % because the copper wire electrode has higher electrical and thermal conductivity than brass wire electrode. In addition, the average dimensional deviation of the parts cut with copper wire decreased from 27 μm to 8 μm compared to the use of brass electrodes, and more precise measurements were obtained.

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“…Radhakrishnan et al [24] explored the influence of vibrations to improve cutting efficiency. Rao et al [25] studied the effect of wire vibration on surface roughness and spark gap when cutting Ti-6Al-4V and established mechanistic models for both. Dwaipayan et al [26] used response surface methodology to test sintered titanium alloy and used the desirability function approach for spark gap, surface unevenness, overcut, and material removal rate optimization.…”

Section: Introductionmentioning

confidence: 99%

Process parameters optimization and performance analysis of micro-complex geometry machining on Ti6Al4V

Farooq,

Ali,

Anwar

et al. 2024

Int J Interact Des Manuf

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The aeronautical industry relies on high-performance equipment that demands materials with exceptional engineering attributes, such as the Ti6Al4V alloy. However, the complexity of the parts used in these applications presents challenges related to stack-up tolerances during assembly. Therefore, conventional machining processes are not economically viable due to their two-step nature solution (machining and surface treatment) and their inability to achieve the required accuracy level, particularly given the alloy’s hard-to-cut nature. In this matter, wire electric discharge machining (WEDM) emerges as an attractive alternative for fabricating complex geometries. This research focuses on evaluating the potential of the WEDM process for machining micro-complex profiles. A comprehensive range of process parameters, including servo voltage (Vs), pulse on time (Ton), pulse off time (Toff), and wire speed (Ws), are studied using a Taguchi-based design of experiments. The results are analyzed through parametric significance analysis, parametric control analysis, surface morphological analysis using scanning electron microscopy, and modified layer analysis. Additionally, both mono-objective and multi-objective process optimization techniques are employed to achieve superior accuracy and speed. The findings indicate that Ton and Ws have the most significant influence on both cutting speed and spark gap, whereas Vs and Toff play a crucial role in determining the accuracy index. In addition, adequate flushing, reduced wire speed (economically viable), and stability of the spark are recommended to attain a lower spark gap and higher accuracy. The confirmatory experiments show that the optimal parametric conditions of Vs = 60 V, Toff = 30 μs, Ton = 8 μs, and Ws = 6 mm/s provide the highest speed of 3.4 mm/min, minimum spark gap of 0.344 mm, and accuracy index of 98.72%. The findings will contribute to enhancing manufacturing efficiency, precision, and cost-effectiveness in the aeronautical industry, meeting the demand for high-quality components with tight tolerances.

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Modeling of kerf width and surface roughness in wire cut electric discharge machining of Ti-6Al-4V

Cited by 16 publications

References 22 publications

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

WEDM ile Kesilen Sleipner Soğuk İş Çeliğinin Kesim Kalitesine Pirinç ve Bakır Tel Kullanımının Etkileri

Process parameters optimization and performance analysis of micro-complex geometry machining on Ti6Al4V

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