Optimization of machining parameters and wire vibration in wire electrical discharge machining process

Abstract

Background: Wire Electrical discharge machining (WEDM) has higher capability for cutting complex shapes with high precision for very hard materials without using high cost of cutting tools. During the WEDM process, the wire behaves like a metal string, straightened by two axial pulling forces and deformed laterally by a sum of forces from the discharge process. Major forces acting on the wire can be classified into three categories. The first is a tensile force, pulling the wire from both sides in axial direction and keeping it straight. The second is the dielectric flushing force that comes from circulation of the dielectric fluid in the machining area. The third category consists of forces of different kinds resulting from sparking and discharging. Large amplitude of wire vibration leads to large kerf widths, low shape accuracies, rough machined surfaces, low cutting speeds and high risk of wire breakage. Such tendencies for poor machining performance due to wire instability behavior appear with thinner wires. Methods: The present work investigates a mathematical modeling solution for correlating the interactive and higher order influences of various parameters affecting wire vibration during the WEDM process through response surface methodology (RSM). The adequacy of the above proposed model has been tested using analysis of variance (ANOVA). Results: Optimal combination of machining parameters such as wire tension, wire running speed, flow rate and servo voltage parameters has been obtained to minimize wire vibration. Conclusions: The analysis of the experimental observations highlights that the wire tension, wire running speed, flow rate and servo voltage in WEDM greatly affect average wire vibration and kerf width.

Variation and artificial neural network prediction of profile areas during slant type taper profiling of triangle at different machining parameters on Hastelloy X by wire electric discharge machining

“…As the variations were very feeble it may have been caused due to wire vibration resulting from sparking. 31,34…”

“…As the variations were very feeble it may have been caused due to wire vibration resulting from sparking. 31,34 Variation of profile areas at different slant angles Figure 4 shows the variation of areas at different slant angles that were machined from various parameters. It can be observed that each parameter yields different areas although the cutting parameters such as pulse on, servo voltage etc.…”

“…As each combination of these input parameters had wire lag, overcut and wire vibration. 31,34 The profiles areas for each parameter also defers irrespective of their dimensions. So the input parameters will contribute to the dimensional accuracy of the profile during machining.…”

Cryogenic Treatment Analysis in WEDM of Al2024/Al2O3/W Composite

“…Moreover, the debris particles which adhered around the wire also generate high KW. When the wire is running at a higher speed the debris and reinforced particles get discarded from the wire surface and resulted in reduced KW [56]. From the 3D surface graph, it can be seen that KW decreases as tension in the wire increases.…”

Influence of Process Parameters on Wire EDM Process for AISI 316 Stainless Steel

“…This scheme uses an unusual plan of orthogonal arrays to cram the whole constraint space with petite number of experiments only. In this study, five machining parameters were used as control factors and each parameter was designed to have three levels, denoted 1, 2 and 3 [14,15,16] . According to the Taguchi quality design concept, a L27 orthogonal array table with 27 rows, analogous to the number of experiments as preferred for the experiments and the consequences are presented in Table 3.…”