Optimization of process parameters on surface integrity in wire electrical discharge machining of tungsten tool YG15

Abstract

This study mainly investigates the effect and optimization of process parameters on surface integrity including white layer thickness and crack density in wire electrical discharge machining (WEDM) of tungsten tool YG15 which is one of the most important hardened stainless steel alloys used in the mold industries. In this paper, four input process parameters including pulse-on time, pulse current, water pressure, and feed rate were set during WEDM experiment, and three output characteristics including surface roughness (SR), white layer thickness (WLT), and surface crack density (SCD) were taken as the performance criteria of surface integrity. Then an experiment for central composite design (CCD) of processing the tungsten tool YG15 has been conducted according to response surface methodology (RSM). After analyzing the experimental results and optimizing the WEDM process using two different methods namely backpropagation neural network combined with genetic algorithm (BPNN-GA) and Non-dominated Sorting Genetic Algorithm-II (NSGA-II), the optimal solution can be obtained. The analysis results manifest that the pulseon time and pulse current have a significant effect on the SR, WLT, and SCD. Moreover, several confirmation tests were carried out to verify the efficiency of the optimization methods, and then the more appropriate method was demonstrated by the comparison of optimization results. According to analysis and discussion of results, the most suitable process parameter combinations can be obtained to guide the actual machine, which contribute to increase the surface integrity and accuracy of WEDM and simultaneously reduce the ratio of disqualification for industrial application.

Optimization of WEDM process of mould material using Kriging model to improve technological performances

“…The parameters were optimized in an effort to improve the working performances for the WEDM processes of SKD11 steel [3], EN 353 steel [4] and AISI D3 [5] material. Additionally, investigators solved the trade-off among multi-responses for the WEDM processes of YG15 steel [6], AISI D2material [7] and Inconel alloys [8,9]. Recently, optimal processing conditions for the WEDM processes of composite materials were studied [10][11][12].…”

Modeling and Analysis of Machining Parameters and Responses of Wirecut Electric Discharge Machining of Al2124/SiCp using Response Surface Methodology and Soft Computing Techniques

“…BPNN-GA is showing less residuals for SR and MRR than RSM. Zhang et al [13] established mathematical models by RSM to study the surface integrity of the WEDM tungsten tool YG15. The response parameters SR, WLT, and SCD are optimized by BPNN-GA for single objective optimization and multi-objective optimization by NSGA II.…”

Integrated optimization model in wire electric discharge machining using Gaussian process regression and wolf pack algorithm approach while machining SiCp/Al composite

“…Azhiri et al 13 used gray relationship analysis (GRA) to maximize the cutting velocity and minimize surface roughness. Rao and Krishna, 4 Kumar and Agarwal, 14 and Zhang et al 15 developed mathematical models to solve the WEDM multiple response problems using the NSGA-II. Previous works [16][17][18][19][20][21][22] applied RSM to obtain the best combination of WEDM process parameters on different materials.…”

“…Main effects plot for MRR: (a) pulse duration (ms)(6,8,10,12,14); (b) pulse interval (ms)(10,15,20); (c) water pressure (kg/cm 2 ) (2, 3, 4); and (d) wire tension (kgf) (5, 6, 7).molten Al cannot be removed from the workpiece and solidified on the surface of workpiece. While fromFigure 6(b)-(d), S q first increases with the increase of pulse interval (T off ), water pressure (W p ), and wire…”

“…Main effects plot for S a : (a) pulse duration (ms)(6,8,10,12,14); (b) pulse interval (ms)(10,15,20); (c) water pressure (kg/cm 2 ) (2, 3, 4); and (d) wire tension (kgf)(5,6,7).…”