Optimization on Material Removal Rate and Surface Roughness of Stainless Steel 304 Wire Cut EDM by Response Surface Methodology

Abstract

In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop products in a very short development cycle and at a better economic rate. In this paper, the selected complex geometry of the metal sample was eroded away from the wire during the WEDM process, which eliminates mechanical tensions during machining. The effect of different WEDM operation variables set as wire speed, wire tension, discharge current, dielectric flow rate, and pulse on and off time on the parameter, stainless steel 304 material removing rate (MRR) using RSM, has been studied. The MRR will be maximized if the optimum sets of operational variations are used and also achieve a superior surface finish.

Investigation of enhancing EDM machining performance of INCONEL alloy using composite electrodes

“…Experiments 1 and 16 utilize non-composite tools made of copper, with a 50% duty cycle and a duty ratio of 0.5. In both cases, no arcing observed [48]. This demonstrates that non-composite tools can handle a higher duty ratio without experiencing arcing.…”

Steady state design and thermal characteristics of a gas turbine blade with lateral holes using finite element analysis

“…Given that air goes from a high-pressure zone to a low-pressure zone, this task might be finished really rapidly. Appropriately placed airfoils allow gases to flow and expand through the turbine's blades and vanes without interruption [22][23][24].…”

Simulation and Optimization of Surface Roughness and Process Performance during Machining of HSS by Micro-WEDM Technology

“…These reasons led us to perform experimental research, the goal of which was to achieve significant progress in optimizing the quality of the machined surface while maintaining high productivity of the electrical discharge process. At the same time, we would like to contribute to the database of already existing knowledge through clear formulations of particular laws in relation to the processes that take place directly on the machined surface during the electrical discharge [ 58 , 59 , 60 , 61 , 62 , 63 , 64 , 65 ].…”