Parametric optimization in wire EDM of D2 tool steel using Taguchi method

Sharma, Sahil; Vates, Umesh Kumar; Bansal, Amit

doi:10.1016/j.matpr.2020.02.802

Cited by 24 publications

(12 citation statements)

References 16 publications

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“…It was reported that the cryogenic treatment significantly influenced both the MRR (decreased 5.6%) and SR (surface finish increased 10.6%) compared to untreated D3 steel. Sharma et al [21] endorsed similar findings on AISI D2 steel.…”

Section: Introductionmentioning

confidence: 62%

“…The effects of four machining variables, namely wire feed (WF), pulse on duration (P on ), open voltage (OV), and servo voltage (SV) have been carefully analyzed on the kerf width (KW), material removal rate (MRR), surface roughness (SR), and recast layer thickness (RLT). The choice of the said input parameters was made based on a comprehensive literature survey [1,[15][16][17][19][20][21][22][23][24][25]. Additionally, preliminary experimentation (six trial experiments) was also performed before the mature experimentation to express the process parameter levels.…”

Section: Methodsmentioning

confidence: 99%

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A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Khan

Rehman

Farooq

et al. 2021

Metals

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Recently, DC53 die steel was introduced to the die and mold industry because of its excellent characteristics i.e., very good machinability and better engineering properties. DC53 demonstrates a strong capability to retain a near-net shape profile of the die, which is a very challenging process with materials. To produce complex and accurate die features, the use of the wire electric discharge machining (WEDM) process takes the lead in the manufacturing industry. However, the challenge is to understand the physical science of the process to improve surface features and service properties. In this study, a detailed yet systematic evaluation of process parameters investigation is made on the influence of a wire feed, pulse on duration, open voltage, and servo voltage on the productivity (material removal rate) and material quality (surface roughness, recast layer thickness, kerf width) against the requirements of mechanical-tooling industry. Based on parametric exploration, wire feed was found the most influential parameter on kerf width: KW (45.64%), pulse on time on surface roughness: SR (84.83%), open voltage on material removal rate: MRR (49.07%) and recast layer thickness: RLT (52.06%). Also, the optimized process parameters resulted in 1.710 µm SR, 10.367 mm3/min MRR, 0.327 mm KW, and 10.443 µm RLT. Moreover, the evolution of surface features and process complexities are thoroughly discussed based on the involved physical science. The recast layer, often considered as a process limitation, was explored with the aim of minimizing the layers’ depth, as well as the recast layer and heat-affected zone. The research provides regression models based on thorough investigation to support machinists for achieving required features.

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Section: Introductionmentioning

confidence: 62%

Section: Methodsmentioning

confidence: 99%

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Khan

Rehman

Farooq

et al. 2021

Metals

View full text Add to dashboard Cite

show abstract

“…Taguchi method is used for optimizing operating parameters in laser additive manufacturing, production of activated carbon from rubber seed shell, inclined plane classifier used for segregating particles of different sizes, and for producing a strong electro-fusion joint [16]- [19]. Several works showed that the implementation of the Taguchi method to various processes resulted in a limited number of experiments to be conducted to obtain the optimal conditions for various manufacturing processes like electrical discharge machining and abrasive water jet machining [20,21].…”

Section: Resultsmentioning

confidence: 99%

Advantages of Taguchi Method compared to Response Surface Methodology for achieving the Best Surface Finish in Wire Electrical Discharge Machining (WEDM)

Kandala¹,

Solomon²,

Arulraj³

2022

JMechE

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Design of Experiments is a method to predict the optimum conditions of a process to reduce the time and number of experiments to be conducted with limited resources. In this paper, a comparative work on design and analysis of experiments between Taguchi method and response surface methodology is carried out in predicting the set of optimal conditions for obtaining the best surface roughness of commercially pure titanium powder metallurgy component using wire electrical discharge machining process. With surface roughness of the Titanium as the response and pulse on time, pulse off time, and sintering temperature of the wire electrical discharge machining process as the affecting factors, the optimum conditions for the surface roughness of the material have been predicted and analysed. Analysis of variance is used to identify the significant factors affecting the system. Both methods gave the same results and the Taguchi approach requires less number of experiments compared to response surface methodology and the predicted surface roughness of the components with the Taguchi method is 2.4 µm, whereas it is between 2.41-3.04 µm with the Response Surface Methodology. The factor Pulse on Time (N) shows a significant effect on the response of the system.

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“…Since this machining process is fully automated, the machining parameters of the thermal process are controlled to eliminate the damage formation and distortion on the surface of the additively manufactured parts. This machining process is commonly employed to produce the parts and components in several fields, such as aerospace, automotive, and electronic industries [1,2].…”

Section: Introductionmentioning

confidence: 99%

Effect of Wire Electrical Discharge Machining on the Surface of Ebm-Additive Manufactured Niti Alloys

PEDUK¹,

Dilibal²

2021

International Journal of 3D Printing Technologies and Digital Industry

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Nickel-titanium (NiTi) shape memory alloys are used in varied engineering products, such as biomedical device and mechatronic actuator applications. The conventional machining technology are utilized in the limited fields due to their effects on the hardness and brittleness of the machined alloys. However, the wire electrical discharge machining (WEDM) technology is one of the most preferred postprocessing tool to obtain a surface with high quality. The electrical current and voltage values with pulse on and pulse off time are the crucial parameters for WEDM. These parameters should be optimized before wire electrical discharge machining process. Electron beam melting (EBM)-based additive manufacturing of the nickel-titanium powders provides obtaining bulk NiTi shape memory alloys using high energy electron beams. In this study, the application of WEDM which is used as a post-processing tool is evaluated for the EBM-based additive manufactured NiTi samples. Additionally, the scanning electron microscopy, elemental analysis and microhardness characteristics results of the wire electrical discharge machined NiTi samples are carefully investigated.

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Parametric optimization in wire EDM of D2 tool steel using Taguchi method

Cited by 24 publications

References 16 publications

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Advantages of Taguchi Method compared to Response Surface Methodology for achieving the Best Surface Finish in Wire Electrical Discharge Machining (WEDM)

Effect of Wire Electrical Discharge Machining on the Surface of Ebm-Additive Manufactured Niti Alloys

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