Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire

Rehman, Mudassar; Khan, Sarmad Ali; Naveed, Rakhshanda

doi:10.1007/s12206-020-0609-2

Cited by 26 publications

(22 citation statements)

References 14 publications

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“…The use of full factorial design as an experimental process involves the consumption of time and cost [32] compared to the Taguchi experimental design. The Taguchi methodology is considered useful because of its precise and robust analysis by a reduction in experimental runs [30]. Consequently, Taguchi's fractional factorial design orthogonal array (OA) has been used for performing the experimentation.…”

Section: Methodsmentioning

confidence: 99%

“…The study quantified the influence of process in enhancing the pulse discharge energy because of the deeper craters produced on the machined surface. Similarly, Rehman et al [30] evaluated gamma wire and resulted the significant influence of P on for C.S (80.21%), KW (48.25%), and MRR (45.21%) during WEDM of DC53 steel.…”

Section: Introductionmentioning

confidence: 90%

“…Variance analysis is considered a decisive tool to determine each process parameter's influence for a certain output response [8,30,33,34]. The insights of this analysis have been To carry out the microscopic examination, samples were prepared by mounting, etching, grinding and polishing.…”

Section: Parametric Significance Analysismentioning

confidence: 99%

“…Variance analysis is considered a decisive tool to determine each process parameter's influence for a certain output response [8,30,33,34]. The insights of this analysis have been reported in Table 3, containing the p-value and percent contribution (PCR).…”

Section: Parametric Significance Analysismentioning

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: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 90%

Section: Parametric Significance Analysismentioning

confidence: 99%

“…Variance analysis is considered a decisive tool to determine each process parameter's influence for a certain output response [8,30,33,34]. The insights of this analysis have been reported in Table 3, containing the p-value and percent contribution (PCR).…”

Section: Parametric Significance Analysismentioning

confidence: 99%

See 2 more Smart Citations

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

Khan

Rehman

Farooq

et al. 2021

Metals

Self Cite

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“…Kerf is defined as the slot produced as a result of material erosion and KW is the measurement of the excessive material removed (width of the cut slot) [ 25 ]. Thus, the slot produced by the laser is called kerf, and the width of that slot is called KW.…”

Section: Quality Characteristics Of Laser Cutting Edgementioning

confidence: 99%

State-Of-The-Art and Trends in CO2 Laser Cutting of Polymeric Materials—A Review

et al. 2020

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Carbon dioxide (CO2) laser cutting finds one of its most relevant applications in the processing of a wide variety of polymeric materials like thermoplastics and thermosetting plastics. Different types of polymeric materials like polypropylene (PP), polymethyl methacrylate (PMMA), low- and high-density polyethylene (LDPE, HDPE), are processed by laser for different household as well as commercial products in the industry. The reason is their easy availability and economical aspect in the market. The problems associated with laser cutting include heat-affected zone (HAZ) generated on the cut surface, kerf width (KW), surface roughness (SR), dross formation, and striations formation. Furthermore, other related problems include taper cutting for deep parts and high-power consumption. The primary purpose of this work is a comprehensive literature review in CO2 laser cutting of polymeric materials. The influence of parametric variation on the cut quality is also explained. Cut quality in terms of KW, SR, HAZ, dross formation, and striations formation is analyzed by optimizing cutting variables like laser power (PL), cutting speed (CS), assist gas pressure (Pg), pulse frequency, nozzle type and its diameter, and stand-off distance (SOD). The effects of the laser cutting on the properties of different thermoplastics/thermosetting materials are also reported. However, this topic requires further studies on exploring the range of polymeric materials, and their optimal parameters selection to improve the cut quality. Therefore, the research gaps and future research directions are also highlighted in the context of CO2 laser cutting for polymeric materials.

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Machinability investigation in electric discharge machining of carbon fiber reinforced composites for aerospace applications

Hassan

Rehman

et al. 2022

Polymer Composites

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Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire

Cited by 26 publications

References 14 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

State-Of-The-Art and Trends in CO2 Laser Cutting of Polymeric Materials—A Review

Machinability investigation in electric discharge machining of carbon fiber reinforced composites for aerospace applications

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