Optimization of Wire Electric Discharge Machining (WEDM) Process Parameters for AISI 1045 Medium Carbon Steel Using Taguchi Design of Experiments

Zaman, Uzair Khaleeq uz; Khan, Usman A.; Aziz, Shahid; Baqai, Aamer Ahmed; Butt, Sajid Ullah; Hussain, Danish; Siadat, Ali; Jung, Dong Won

doi:10.3390/ma15217846

Cited by 15 publications

(7 citation statements)

References 42 publications

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“…Figure 7 m illustrates how the MRR increases progressively as the feed increases. Additionally, in line with what was reported in [ 27 , 31 ], with the increase in current, the MRR for all feed levels saw a slight increase. Figure 7 o,p show that the material removal rate increases with the increasing pulse-off time for different pulse-on time values.…”

Section: Resultssupporting

confidence: 91%

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304

2023

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Its unexcelled mechanical and physical properties, in addition to its biocompatibility, have made stainless steel 304 a prime candidate for a wide range of applications. Among different manufacturing techniques, electrical discharge machining (EDM) has shown high potential in processing stainless steel 304 in a controllable manner. This paper reports the results of an experimental investigation into the effect of the process parameters on the obtainable surface roughness and material removal rate of stainless steel 304, when slotted using wire EDM. A full factorial design of the experiment was followed when conducting experimental trials in which the effects of the different levels of the five process parameters; applied voltage, traverse feed, pulse-on time, pulse-off time, and current intensity were investigated. The geometry of the cut slots was characterized using the MATLAB image processing toolbox to detect the edge and precise width of the cut slot along its entire length to determine the material removal rate. In addition, the surface roughness of the side walls of the slots were characterized, and the roughness average was evaluated for the range of the process parameters being examined. The effect of the five process parameters on both responses were studied, and the results revealed that the material removal rate is significantly influenced by feed (p-value = 9.72 × 10−29), followed by current tension (p-value = 6.02 × 10−7), and voltage (p-value = 3.77 × 10−5), while the most significant parameters affecting the surface roughness are current tension (p-value = 1.89 × 10−7), followed by pulse-on time (1.602 × 10−5), and pulse-off time (0.0204). The developed regression models and associated prediction plots offer a reliable tool to predict the effect of the process parameters, and thus enable the optimizing of their effects on both responses; surface roughness and material removal rate. The results also reveal the trade-off between the effect of significant process parameters on the material removal rate and surface roughness. This points out the need for a robust multi-objective optimization technique to identify the process window for obtaining high quality surfaces while keeping the material removal rate as high as possible.

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Section: Resultssupporting

confidence: 91%

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304

2023

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“…A variety of operations can be carried out on AISI 1045 steel using the proper feeds, tool kinds, and speeds, depending on the manufacturer's recommendations. [16] Rajusing Rathod et al, provided an overview of the titanium alloy performance evaluation using electric discharge machining. Titanium alloy is a noncorrosive material with exceptional mechanical qualities, high specific resistance, and good machining performance.…”

Section: Literature Reviewmentioning

confidence: 99%

Recent Research in Wire Cut Electrical Discharge Machining Process

2024

jmc

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A product's shape and size are developed through the manufacturing process, which is essential to all sectors. With its unique thermal machining technique, Wire Cut Electrical Discharge Machining (WEDM), items with sharp edges and varied hardness that prove challenging to produce using conventional machining methods can be precisely machined. Utilizing the widely used non-contact material removal technique, the practical technology of the WEDM process is based on the typical EDM sparking phenomenon. When the process was first introduced, WEDM has developed from a crude way to make tools and dies to the best way to produce micro-scale parts with the highest level of surface finish quality and dimensional accuracy. This paper reviews the extensive amount of research done from the EDM process to the development of the WEDM. It reports on the WEDM research that involves optimizing the process parameters and examining the impact of various factors on productivity and machining performance. The impact of multiple WEDM process input parameters, including wire speed, peak current, pulse on and off times, and peak on material removal rate (MRR), surface roughness (Ra), and micro structural analysis, on various process output responses is reviewed in this study.

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“…The performance of wire electrical discharge machining was also investigated, as well as the impact of deep cryogenic treatment on brass wire electrodes. The most effective parameters for the maximum material removal rate were investigated using a Taguchi experimental design [27]. Asarudheen et al [28] investigated how di-electric fluid also plays a role in machinability.…”

Section: Introductionmentioning

confidence: 99%

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

Kosaraju¹,

Bobba²,

Salkuti

2023

Materials

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Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.

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Optimization of Wire Electric Discharge Machining (WEDM) Process Parameters for AISI 1045 Medium Carbon Steel Using Taguchi Design of Experiments

Cited by 15 publications

References 42 publications

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304

Recent Research in Wire Cut Electrical Discharge Machining Process

Optimization and Microstructural Studies on the Machining of Inconel 600 in WEDM Using Untreated and Cryogenically Treated Zinc Electrodes

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