Variation and artificial neural network prediction of profile areas during slant type taper profiling of triangle at different machining parameters on Hastelloy X by wire electric discharge machining

Abstract

<jats:p> In the present research work, an in-house developed fixture is used to achieve taper profiles which avoids the disadvantages in convention tapering operation in wire electric discharge machining like wire bend, inaccuracies in taper, insufficient flushing, guide wear etc. A simple triangular profile was machined at 0°, 15° and 30° slant/taper angles. These taper profile areas are investigated for various machining parameters like wire guide distance, corner dwell time, wire offset and cutting speed override. It is observed that as the wire guide distance and cutting speed override increases, the profile area decreases. Whereas in case of wire offset, as offset increases the profile areas also increase. The corner dwell time parameter do not effect on the profile area. The taper profile areas measured highest at 30° followed by 15° and 0° slant angles. This is due to the workpiece placed at different angles during machining with the aid of fixture to obtain taper profile. The taper angle represents the angularity of slant triangular profiles. As the slant angle increases the variation in taper error also increases due to higher wire vibration. An artificial neural network model is developed for the prediction of these areas at a different slant angle. The model is validated experimentally where the errors in prediction ranged from 1% to 9%. In conclusion, it can be noticed that the machining parameters and slant angle influence on profiles irrespective of their dimensions. </jats:p>

Examination of Machining Parameters and Prediction of Cutting Velocity and Surface Roughness Using RSM and ANN Using WEDM of Altemp HX

“…Soni et al [18] used the response surface method and ANN for the prediction of cutting speed in WEDM of shape memory alloys. Manoj and Narendranath [19,20] have used ANN for the prediction of profile areas and profiling speed. It was concluded that both machining parameters and taper angle influence the accuracy and profiling speed.…”

Slant type taper profiling and prediction of profiling speed for a circular profile during in wire electric discharge machining using Hastelloy-X

“…As the u parameter increases the profile area also increases with certain offset distance. 23,29 As u increases, the wire has to travel lager circumference compared to the programmed profile which increases the wire vibrations. 25,27,29 This leads to small variations in the increase as seen at 40mm for 0 , 15 and 30 of 1 mm taper profiles.…”

“…23,29 As u increases, the wire has to travel lager circumference compared to the programmed profile which increases the wire vibrations. 25,27,29 This leads to small variations in the increase as seen at 40mm for 0 , 15 and 30 of 1 mm taper profiles. With the increase in u parameter, the circular area also increases as shown in Figure 5 (a) this can be seen in all the taper angles.…”

“…23 With the increase in # parameter, the wire lag and wire vibration escalate because of the tension in the wire decreases at higher spans. 29 The parameters in bold highlight that it was the highest contributing factor among other parameters.…”

A Novel Flushing Mechanism to Minimize Roughness and Dimensional Errors during Wire Electric Discharge Machining of Complex Profiles on Inconel 718

“…The supremacy of the brass electrode was established through effective discharge energy transfer. Manoj and Narenderanath [ 14 ] machined triangular profiles having 0°, 15°, and 30° taper angles to study inaccuracy at Hastelloy X (nickel alloy). They found that insufficient flushing attributed to the generation of wire vibrations which increased slant angle inaccuracies (taper error).…”