Study on Optimization of WEDM Process Parameters on Stainless Steel

Natarajan, K.; Ramakrishnan, H.; Gacem, Amel; Vijayan, V.; Karthiga, K.; Ali, Heba; Prakash, B.; Mekonnen, Addisalem

doi:10.1155/2022/6765721

Cited by 24 publications

(2 citation statements)

References 42 publications

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“…The growth and development of the machining process have caused the need to produce form tools with high hardness and complex shapes to be considered. Using the wire electrical discharge process to produce form tools is a method that can achieve this because of its unique features [18]. The input parameters of the electric discharge process with wire are: pulse on time, pulse off time, peak current, material removal rate, servo voltage, gap, narrow gap, gap voltage, guides, and wire tension.…”

Section: Production Techniques For Form Cutting Tools: a Comparative ...mentioning

confidence: 99%

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Alinaghizadeh,

Hadad,

Azarhoushang

2023

Micromachines

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In this research, a comparison between two methods of grinding and WEDM and the chip formation of each form tool was studied through a set of designs of experiments. A multi-functional form tool with different cutting-edge shapes was designed to compare different production methods, and a grinding machine and a five-axis wire-cutting machine were made. The form tools by the wire cutting method were made with three different machining states, rough, semi-finish, and finish. The results of the experimental test showed that the chip formation of the finished surface of the wire cut tool was close to the ground tools. Additionally, the tool life in wear generation was assessed, revealing that the tool generated through the wire-cutting method with three passes exhibited superior performance compared to alternative approaches. Furthermore, employing the wire-cutting technique with high surface finishing yielded optimal outcomes for producing form-cutting tools featuring complex profiles.

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Section: Production Techniques For Form Cutting Tools: a Comparative ...mentioning

confidence: 99%

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Alinaghizadeh,

Hadad,

Azarhoushang

2023

Micromachines

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“…As spark energy is inversely proportional to current and Ton, this was caused by the greater spark energy available for melting material from workpiece surfaces. High spark energy causes the plasma channel pressure to rise, producing an impulsive force and erratic surfaces [45]. This raises the machined zone's SR.…”

Section: Effect Of Near-dry Wedm Variables On Output Measuresmentioning

confidence: 99%

Effect of Near-Dry WEDM Process Variables through Taguchi-Based-GRA Approach on Performance Measures of Nitinol

Vora

Shah

Khanna³

et al. 2022

JMMP

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The machining of Nitinol shape memory alloys (SMA) through conventional machining techniques imposes several challenges due to the alloys’ comprehensive mechanical qualities. Wire electrical discharge machining (WEDM) process is a non-conventional machining technique that is suitable mainly for producing complex shape geometries with excellent surface features for difficult-to-cut materials. The current study attempted the use of a near-dry WEDM process for Nitinol SMA with the consideration of multiple response variables. The studied literature and machine capabilities have identified input factors of pulse-on-time (Ton), pulse-off-time (Toff), and current and output factors of MRR, SR, and RLT. Through the Taguchi approach, a total of nine experimental trials were designed to analyze the performance of the process. The statistical significance of input factors on the performance measures was studied with the help of ANOVA techniques. Statistical analysis for all the output measures has shown that the generated regression terms had a significant influence. For single output measures, the current was found to have a substantial effect on both MRR and SR, while Toff was the most significant contributor in the case of RLT. The obtained results of residual plots for all performance measures implied good ANOVA results. The effect of near-dry WEDM variables was studied on output measures through main effect plots. Grey relational analysis (GRA) has been employed to attain optimal parametric settings of multiple performance measures. GRA technique for the optimal parametric settings of simultaneous performance measures of MRR, SR, and RLT was found to have a Ton of 30 µs, Toff of 24 µs, and current of 4 A. Validation trials were conducted to check the adequacy of the GRA technique. The minor acceptable deviation was recorded among the anticipated and recorded values. This clearly reveals the acceptability of the integrated approach of the Taguchi–Grey method. The surface morphology for the near-dry and wet-WEDM has also been investigated through scanning electron microscopy (SEM). The author considers that the present study will be beneficial for users working in WEDM and near-dry WEDM processes for hard machining materials.

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Effect of Mg on the Microstructure, Mechanical Properties, and Surface Roughness of Functionally Graded A413 Composite: Machine Learning Approach at Wire‐Cut Electric Discharge Machining Zone

Natarajan,

Ramanathan,

Chenrayan

et al. 2024

Adv Eng Mater

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The present study assists the industrial sectors by implementing low‐weight high‐strength aluminium composite. The pristine magnesium as a reinforcement in three different weight percentages (3.5, 7, and 10.5) is utilized to fabricate the A 413 composite using centrifugal casting. The density analysis concludes a higher level of Mg inclusion prompts the material to save 3.9% of weight. Microstructural study of centrifugal casting specimens reveal a rich existence of hard phase Mg2Si in the outer zone, with its richness decreasing toward the inner zone. The tensile test result affirms the functionally graded nature of the material with the increasing trend of tensile strength from the inner to the outer. Fractured surface analysis concludes the existence of cracks and their propagation for the inner region specimen. The influence of magnesium on the surface finish of functionally graded composite at the wire cut electric discharge machining (WEDM) zone is predicted using a machine learning‐based random forest regressor (RFR) algorithm. The supervised learning algorithm declares that 10.5 wt% of Mg facilitates the minimal surface roughness of 0.229 µm with the optimal combination of parameters 6 A of current, 115 µs of pulse‐on time, 60 µs of pulse‐off time, and 8 N of wire tension.

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Study on Optimization of WEDM Process Parameters on Stainless Steel

Cited by 24 publications

References 42 publications

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes

Effect of Near-Dry WEDM Process Variables through Taguchi-Based-GRA Approach on Performance Measures of Nitinol

Effect of Mg on the Microstructure, Mechanical Properties, and Surface Roughness of Functionally Graded A413 Composite: Machine Learning Approach at Wire‐Cut Electric Discharge Machining Zone

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