Precision Control of Kerf in Metal Cutting Using Dry Micro WEDM: Issues and Challenges

Ali, Mohammad Yeakub; Banu, Asfana; Rahman, Mohamed Abdul; Hazza, Muataz Hazza Faizi Al; Adesta, Erry Yulian Triblas

doi:10.4028/www.scientific.net/kem.775.499

Cited by 5 publications

(3 citation statements)

References 23 publications

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“…The strength and short circuit issues [50][51][52]. The wire-work piece sticking, discrete sparks, insufficient heat energy, and unstable cutting problems are significant problems observed during the dry WEDM process.…”

Section: Preliminary Experiments Comparative Analysismentioning

confidence: 99%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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In this research, the mixing of compressed air with the minimum quantity of water is used as a dielectric medium and the cryogenically cooled molybdenum wire is used as a tool in wire-cut electrical discharge machining (WEDM) to encourage the eco-friendly production, called cryogenically cooled near-dry WEDM process. The nitrogen gas-cooled wire tool is utilized to cut the Inconel 718 alloy workpiece to prevent wire breakage and maintain enough electrical conductivity. The preliminary experiments were conducted to compare wet, dry, near-dry, and cryogenically cooled near-dry WEDM processes. It was revealed that cryogenic cooled near-dry WEDM is better performance than dry, near-dry WEDM except for the wet process. The systematic experiments of eco-friendly cryogenically cooled near-dry WEDM have been conducted to analyse the effect of input factors like spark current, pulse-width, pulse-interval, and mixing water flow rate on material removal rate (MRR) and surface roughness (SR) using Box–Behnken method. The fitted models and response surface graphs were developed to analyse the influences of input factors on each response parameter. It was concluded that MRR and SR of cryogenically cooled near-dry WEDM are increased by maximizing spark current, pulse-width, and flow rate, conversely, both responses were decreased by increasing pulse-interval. The technique for order of preference by similarity to ideal solution (TOPSIS) technique has been applied to predict the best combination of input factors for satisfying the optimal values of both responses.

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Section: Preliminary Experiments Comparative Analysismentioning

confidence: 99%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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“…Moreover, one of the key functions of the dielectric fluid is to restrict the spark generation where higher density of energy is achievable during the machining process. This mechanism is only applicable when the dielectric fluid is in the liquid form [13][14][15]. Normally, the dynamic plasma pressure rises and the bubble of vapour expands when the sparks are in the liquid dielectric.…”

Section: Introductionmentioning

confidence: 99%

“…Normally, the dynamic plasma pressure rises and the bubble of vapour expands when the sparks are in the liquid dielectric. However, due to the restriction of the plasma growth caused by the surrounding of the liquid dielectric, the bubble collapses and removes the molten metal out of the crater when the temperature decreases [13,14]. As a result, higher amount of materials is removed when the liquid dielectric is used during the machining process compared to the gas dielectric [15].…”

Section: Introductionmentioning

confidence: 99%

Stability of micro dry wire EDM: OFAT and DOE method

Banu

Ali

Rahman

et al. 2020

Int J Adv Manuf Technol

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Micro dry wire electrical discharge machining (μDWEDM) is an environmental-friendly machining process where gas is used as the dielectric fluid instead of liquid. In this process, certain modifications of wire electrical discharge machining (WEDM) are required during the machining operation for stable machining. In μDWEDM, the process is considered stable if the machining is continuous without any interruption due to wire breakage or wire lag. However, in the present state of the arts, stable and smooth machining process using μDWEDM remains a critical issue. Hence, the objectives of this research are to establish a stable μDWEDM process using two different experimental approaches: one-factor-at-a-time (OFAT) and design of experiment (DOE) method. The investigation was performed on a stainless steel (SS304) with a tungsten wire as the electrode using integrated multiprocess machine tool, DT 110 (Mikrotools Inc., Singapore). Types of dielectric fluid, dielectric fluid pressure, polarity, threshold voltage, wire tension, wire feed rate, wire speed, gap voltage, and capacitance were the controlled parameters. The machining length of the microchannels was measured using scanning electron microscope (SEM) (JEOL JSM-5600, Japan). Analysis based on these two experimental approaches shows that stable μDWEDM process is achievable when the types of dielectric fluid, dielectric fluid pressure, polarity, threshold voltage, wire tension, wire feed rate, and wire speed remain as the fixed parameters while the capacitance and gap voltage remain as the controlled parameters.

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