Multi-Response Optimization and Surface Integrity Characteristics of Wire Electric Discharge Machining α-Phase Ti-6242 Alloy

Prasanna, R; Kavimani, V.; P.M, Gopal; Simson, D.

doi:10.1007/s41660-021-00179-2

Cited by 5 publications

(3 citation statements)

References 30 publications

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“…Accordingly, various approaches have been employed for predicting and optimizing process parameters in EDM and WEDM of Ti-6242. These approaches are based on the notion of metal machining, design of experiment (DOE) method, Taguchi method and the response surface methodology approach (RSA) [19,23,[25][26][27][28][29]. For instance, to improve the MRR and reduce the over cut and tool wear rate in EDM of Ti-6242, Taguchi based grey relational analysis method using L27 orthogonal array with multi response optimization has been used by Perumal et al…”

Section: Introductionmentioning

confidence: 99%

“…(2020) [23]. Taguchi method was employed by Prasanna et al (2021) [25] to identify optimal parameter combination for attaining minimal surface roughness in WEDM of Ti-6242. Even though being a material with very strong implication in industrial applications, the investigation of the surface roughness and the in uencing setting parameters in WEDM of Ti-6242 super alloy has been presented by few studies and resultantly captured little interest.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, Shather et al (2021) [24] have investigated the nano dielectric effect in WEDM of Ti-6242 to improve process e ciency in particular increasing the MRR. Prasanna et al (2021) [25] have studied the effect of some WEDM process inputs mainly pulse on time, voltage, and wire feed rate on MRR and surface integrity of Ti-6242. The obtained results show that surface roughness is highly affected by wire feed rate and voltage, and the MRR in WEDM of Ti-6242 is improved when the pulse on time is increased.…”

Section: Introductionmentioning

confidence: 99%

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An Investigation To Achieve a Good Surface Integrity in WEDM of Ti-6242 Super Alloy

Ezeddini

Rajhi

Boujelbene

et al. 2021

Preprint

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Ti-6242 is a super alloy which exhibits the best creep resistance among available titanium alloys and is widely used in the manufacture by WEDM of aircraft engine turbomachinery components. However, the final quality of wire EDMed surface is a great challenge as it is affected by various factors that need optimization for surface integrity and machine efficiency improvement. The aim of this study is to investigate the effect of a set of cutting process parameters such as pulse on time (Ton), servo voltage (U), feed rate (S) and flushing pressure (p) on surface roughness (SR) when machining Ti-6242 super alloy by WEDM process using a brass tool electrode and deionized water as a dielectric fluid. WEDM experiments were conducted, and SR (Ra) measurement was carried out using a 3D optical surface roughness-meter (3D–SurfaScan). As a tool to optimize cutting parameters for SR improvement, Taguchi's signal‐to‐noise ratio (S/N) approach was applied using L9 (3^4) orthogonal array and Lower-The-Better (LTB) criteria. Substantially, the findings from current investigation suggest the application of the values 0.9 µs, 100V, 29 mm/min, and 60 bar for Ton, U, S and p cutting parameters, respectively, for producing a good surface finish quality. Percent contributions of the machining parameters on SR (Ra) assessed based on ANOVA analysis are 62.94%, 20.84%, 11.46% and 4.74% for U, S, Ton and p, respectively. Subsequently, accurate predictive model for SR (Ra) is established based on response surface analysis (RSA). The contour plots for SR (Ra) indicate that when flushing pressure p converges to a critical value (80 bar), a poor-quality surface finish is highly expected with the excessive increase in U and S. Electron microscope scanning (SEM) observations have been performed on machined surface for a wide range of cutting parameters to characterize wire EDMed surface of Ti-6242. SEM micrographs indicate that the machined surface acquires a foamy structure and shows white layer and machining-induced damage that the characteristics are highly dependent on cutting parameters. At high servo-voltage, the decrease in pulse on time Ton and feed rate S results in a large decrease in overall machining-induced surface damage. Moreover, for high servo-voltage and feed rate levels, it has been observed that pulse on time could play a role of controlling the surface microcracks density. In fact, the use of a low pulse duration of cut combined with high servo-voltage and feed rate has been shown to inhibit surface microcracks formation giving the material surface a better resistance to cracking than at high pulse duration.

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