Saad Shather - Academia.edu (original) (raw)
Papers by Saad Shather
Engineering and Technology Journal, 2018
This work is focused on some affecting parameters in Wire electrical discharge machining process ... more This work is focused on some affecting parameters in Wire electrical discharge machining process for AISI 1012 steel by using brass wire and zinc coated brass wire with 0.25mm diameter. Pulse on time, pulse off time, spark gap voltage and servo feed had been studied as input parameters while wire wear ratio, metal removal rate and surface roughness were the outputs. The experiments showed that increasing pulse on time would increase wire wear ratio, metal removal rate and surface roughness. While, increasing pulse off time, spark gap voltage and servo feed will cause a little increase in wire wear ratio, decrease metal removal rate and improve surface roughness. Artificial Neural Network had been used to predict the process outputs for 16 samples, which gave good results and agreement with experimental results. Analysis of Variance had been used to find the contribution of the process parameters on outputs.
Engineering and Technology Journal
The effect of jet pressure, feed rate, and standoff distance on material removal rate throughout ... more The effect of jet pressure, feed rate, and standoff distance on material removal rate throughout abrasive water jet cutting of carbon steel metal workpieces were studied. The experimental results showed that feed rate and pressure jet had the most effect on material removal rate. The most influencing factors for getting a better material removal rate are pressure jet and feed rate. Abrasive water jet (AWJ) is one of the most advanced and valuable nontraditional machining processes because of its massive advantages of removing metal from hard and soft metals. This paper has studied the effect of jet pressure, feed rate, and standoff distance on material removal rate throughout abrasive water jet cutting of carbon steel metal workpieces. The material removal rate was assessed using a precision balance device by performing sixteen experiments to identify the ratio of weight loss to total cutting time. The Taguchi method was introduced to implement the experiments and indicate the most influential process parameters on material removal rate. The experimental results showed that feed rate and pressure jet had the most effect on material removal rate. The best material removal rate value was 3.71 g/min at jet pressure 300 MPa, feed rate 30 mm/min, and standoff distance 4mm.
Engineering and Technology Journal, 2020
In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental F... more In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.
Engineering and Technology Journal, 2020
The Electro discharge machine that named (EDM) is used to remove the metal from the workpiece by ... more The Electro discharge machine that named (EDM) is used to remove the metal from the workpiece by spark erosion. The work of this machining depends on the multiple variables. One of the most influential variants of this machine is the polarity, the material of the electrode, the current and the time pulses. Essentially the polarity of the tool (electrode) positive and the work piece is negative, this polarity can be reversed in this paper was reversed the polarity that was made the tool (electrode) negative and the work piece was positive. The aim of this paper was focused on the influence of reversed the polarity (negative) with changing the electrode metal (copper and graphite) on the surface roughness and metal removal rate by using different parameters (current and pulses of time). Experiments show that: the copper electrode gives (best surface roughness 0.46 µm when the current 5 Am and Ton 5.5 µs) and (worst surface roughness 1.66 µm when the current is 8 A and Ton 25 µs). And...
University of Technology, Baghdad, IRAQ
In this study the authors attempt to present a climatology of the cut-off low systems (COLs) for ... more In this study the authors attempt to present a climatology of the cut-off low systems (COLs) for the Greater European Alpine region (GAR). The presented climatology is based on an algorithm which uses physically based criteria to detect COLs in the European Center for Medium-Range Weather Forecasts reanalysis ERA-40 dataset. Moreover, an in depth analysis is carried out to understand the relationship between COLs and extreme precipitation events which can affect large areas (~75 sq. km is considered) in the GAR. This is achieved by coupling the algorithm with the Swiss Federal Institute of Technology Zurich precipitation dataset. The presented analysis also highlights the relevance and importance of COLs in manifestation of Alpine extreme precipitation events.
IOP Conference Series: Materials Science and Engineering, 2021
The present paper focuses on the wire electrical discharge machining (WEDM) of titanium alloys. I... more The present paper focuses on the wire electrical discharge machining (WEDM) of titanium alloys. It can be considered as an attempt to develop two dielectrics in the WEDM significantly affects the efficiency of machining. This paper explores surface ruggedness during the processing of titanium of various dielectric fluids, including demineralized water and dielectric alumina. The findings show that dielectric alumina as a dielectric produces decreased ruggedness on the surface. Also, surface rudeness is better for demineralized water as the dielectric powder is mixed with non-conductive alumina powder. Many dielectric liquids show that surface ruggedness decreases. Alumina powder and ethylene glycol to dielectric water. A comparative surface roughness analysis for different dielectric fluids was also performed. Using surface roughness to analyze surface roughness is further studied. Conducting a further investigation to use the response surface method (RSM) on surface integrity in ea...
˜Al-œKhawarizmi engineering journal, 2015
Experimental work from Magnetic Abrasive Finishing (MAF) tests was carried out design parameters ... more Experimental work from Magnetic Abrasive Finishing (MAF) tests was carried out design parameters (amplitude, and number of cycle which are formed the shape of electromagnetic pole), and technological parameters (current, cutting speed, working gap, and finishing time) all have an influence on the mechanical properties of the surface layer in MAF process. This research has made to study the effect of design and technological parameters on the surface roughness (Ra), micro hardness (Hv) and material removal (MR) in working zone. A set of experimental tests has been planned using response surface methodology according to Taguchi matrix (36) with three levels and six factors. The analysis of variance and instruction curves indicate some significant. X1; X4; X6 have a significant effect on the surface roughness Ra for steel, X2 has mildly significant, while X3 and X5 have insignificant effect. The results showed that roughness of workpiece decreased from 0.3 to 0.15 µm that means improve...
Electrochemical Machining (ECM) is a relatively important method of removing metal by anodic diss... more Electrochemical Machining (ECM) is a relatively important method of removing metal by anodic dissolution. In this research the ECM was used to remove the metals from the internal hole of the workpiece.The tool used was made from brass. This research focuses on the parameters of the change in gap size, the change in current density, and the change of the tool roughness on the Material Removal Rate (MRR), and Surface Roughness of the workpiece. The Statistical Package for Social Science (SPSS) software was used to predict the results. It was found that for the surface roughness the coefficient of determination of the prediction was (0.982) and the accuracy of prediction (97.15%). For the Material Removal Rate in (g/sec) units the coefficient of determination of predicts was (0.991) with accuracy of prediction (98.29%).
2019 Southern African Universities Power Engineering Conference/Robotics and Mechatronics/Pattern Recognition Association of South Africa (SAUPEC/RobMech/PRASA), 2019
Due to kinematic, physical, or operational constraints in terrain types, it is necessary for a mo... more Due to kinematic, physical, or operational constraints in terrain types, it is necessary for a mobile robot to be able to quantify the traversability characteristics of its environment to ensure safe and efficient navigation. The Gaussian Process Regression approach is a supervised method which promises to add completeness to one of the aspects of traversability analyses, namely environment modelling. This paper presents experimental results which demonstrate the effectiveness of Gaussian Process Regression in predicting the values of missing data for artificial environment features as well as actual collected point cloud data. The study concludes that when there are sufficient points the regression fits more closely to the features in the data set, with less error. Also, the prediction model produced by the Gaussian Process Regression method can be useful during robot operation to improve the terrain modelling.
Engineering and Technology Journal
Electrical discharge machining (EDM) is one of the most common non-traditional processes for the ... more Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.
Engineering and Technology Journal
Discharge Machining is a non-traditional machining technique and usually applied for hard metals ... more Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The...
Engineering and Technology Journal
Increase the demand to produce complex shapes with high quality and dimensional accuracy such as ... more Increase the demand to produce complex shapes with high quality and dimensional accuracy such as production aerospace, cars, die sinking has been leading to increase the demand to use the non- traditional cutting operations such as wire electro-discharge machine (WEDM) rather than using the traditional operations. An idea to understand the effect of wire diameter, wire feed, pulsing (on/off) time on surface roughness, and metal removal rate of Cr-Mo steel during wire electrical discharge machining was investigated. Two Steel alloy samples with dimensions of (60 x50 x 20)mm were cut into four rectangular spaces with (5x10x20)mm at one side of each sample using wire cut (EDM) machine with a wire diameter of 0.25 mm and feeding rate 2 m/min for sample 1 and a 0.3 mm diameter and 3 m/min feeding rate for sample 2. Pulse (on, off) time was (110, 50), (112, 52), (115, 55), (116, 57) corresponds to space 1, space 2, space 3, and space 4 in both steel block. Surface roughness and metal remo...
IOP Conference Series: Materials Science and Engineering
2ND INTERNATIONAL CONFERENCE ON MATERIALS ENGINEERING & SCIENCE (IConMEAS 2019)
Engineering and Technology Journal
The presented study has the aim of finding out the relationships between input variables and proc... more The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected on HAZ with 67.219% contribution.
Diyala Journal of Engineering Sciences
This paper focuses on intervening variables in wire cut process such as pulse on time, pulse off ... more This paper focuses on intervening variables in wire cut process such as pulse on time, pulse off time, voltage, type of wire which use in experiments, it finds that all values from experiments to use in statistical package of social science model. The R square pieces are (0.998). Also they Show that 99.8% of the observed variability in material removal rate can explain by the independent variables. The multiple R is 0.999 for coat wire. This means that the correlation coefficient between the observed value of the dependent variable and the predicted value base on the regression model which are high as this means that the statistical model could predict. The Ra with about 98.7 % and 96.8 % accuracy of the testing data set for coat wire respectively. 1-INTRODUCTION Wire EDM has introduced in the late 1960s', and has revolutionized the tool and die, mold, and metal working industries. It has probably the most exciting and diversified machine tool to develop for this industry in the last fifty years, and has numerous advantages to offer. It can machine anything that has electrically conductive regardless of the hardness, from relatively common materials such as tool steel, aluminum, copper, and graphite, to exotic space-age alloys including in conel, titanium, carbide, polycrystalline diamond compacts and conductive ceramics [1]. Wire cut process has one of thermal nontraditional machining which has important applications and most widely in different industries, electrical discharge machining which has based on the principle of removing material by repeated electrical discharges between the tool termed as electrode and the workpiece in the presence of a dielectric fluid [2].The wire has not touch the workpiece, so there has no physical pressure imparted on the workpiece compared to grinding wheels and milling cutters[3]. The amount of clamping pressure has required to hold small, thin and fragile parts have minimal, preventing damage or distortion to the workpiece. The accuracy, surface finish and time have required to complete a job which have extremely predictable, making it much easier to quote, EDM leaves a totally random pattern on the surface as compared to tooling marks left by milling cutters and grinding wheels. The EDM process have leave no residual burrs on the workpiece, which have reduced or eliminates the need for subsequent finishing operations [4]. Wire EDM has also given designers more latitude in designing dies, and management more control of manufacturing, since the machining has completed automatically [5]. Parts have complex geometry and tolerances has not required you to rely on different skill levels or multiple equipments. Substantial has increased in productivity which has achieved, since the machining has untended, allowing operators to do work in other areas. Most machines have run overnight in a "lights-out" environment [6]. Long jobs have cutten overnight, or over the weekend, while shorter jobs have scheduled during the day. Most workpieces have comen off the machine as a finished part, without the need for secondary operations. It's a one-step process[5] .today has important applications in manufacturing solar cells which led to high Diyala Journal of Engineering Sciences EXPERIMENTAL INVESTIGATION TO PREDICT METAL REMOVAL AND SURFACE ROUGHNESS IN WIRE CUT PROCESS
IOP Conference Series: Materials Science and Engineering
The present work is aimed to improve the thermal effects of electrical discharge machining (EDM) ... more The present work is aimed to improve the thermal effects of electrical discharge machining (EDM) by EDM/ECM hybrid process. A hybrid method of EDM-ECM combined processing involve EDM shaping as well as electrochemical machining (ECM) finishing, also, they are conducted in sequence one same machine tool, same electrode, yet on the different dielectric. Concerning the process of EDM, the material will be removed via the vaporization and melting throughout all electric discharges. Thus, thermally damaged layers make the machined surface. In this study, the used workpiece material is the A2-Tool Steel material, while the electrode material is copper. The influence of controllable parameters could be identified via RSM, which is an abbreviation for Response surface methodology, these controllable effects include: pulse current, pulse on time, pulse off time, gap, voltage, and electrolyte concentration on white layer thickness (WLT) and Surface Roughness (SR). It has been noticed that mod...
Engineering and Technology Journal
Electro discharge machining (EDM) is one of non-traditional machining processes which is used in ... more Electro discharge machining (EDM) is one of non-traditional machining processes which is used in important application. This paper has focused on improving material removal rate by adding powders (Al 2 O 3 particle size 15-35m) and (SiO 2 particle size 20-30m) to kerosene solution through EDM process with different ratios (0.1, 0.14, 0.18 to 0.25 g) particle size for each liter using different values of currents (8, 16 and 30 Amp) and (140 Volt) and (Toff, Ton 25 and 37 μSec), Medium carbon steel is used as a workpeice and copper as electrode, the material removal rate (MRR). It has been found that maximum MRR was (0.2969) g/min when adding SiO 2 powder (0.25)g/l and maximum MRR was (0.2781)g/min when adding Al 2 O 3 powder (0.25)g/l, the Minitab model program was used to predict the MRR which gives a good result and agreement with experiments 99%.
Engineering and Technology Journal, 2018
This work is focused on some affecting parameters in Wire electrical discharge machining process ... more This work is focused on some affecting parameters in Wire electrical discharge machining process for AISI 1012 steel by using brass wire and zinc coated brass wire with 0.25mm diameter. Pulse on time, pulse off time, spark gap voltage and servo feed had been studied as input parameters while wire wear ratio, metal removal rate and surface roughness were the outputs. The experiments showed that increasing pulse on time would increase wire wear ratio, metal removal rate and surface roughness. While, increasing pulse off time, spark gap voltage and servo feed will cause a little increase in wire wear ratio, decrease metal removal rate and improve surface roughness. Artificial Neural Network had been used to predict the process outputs for 16 samples, which gave good results and agreement with experimental results. Analysis of Variance had been used to find the contribution of the process parameters on outputs.
Engineering and Technology Journal
The effect of jet pressure, feed rate, and standoff distance on material removal rate throughout ... more The effect of jet pressure, feed rate, and standoff distance on material removal rate throughout abrasive water jet cutting of carbon steel metal workpieces were studied. The experimental results showed that feed rate and pressure jet had the most effect on material removal rate. The most influencing factors for getting a better material removal rate are pressure jet and feed rate. Abrasive water jet (AWJ) is one of the most advanced and valuable nontraditional machining processes because of its massive advantages of removing metal from hard and soft metals. This paper has studied the effect of jet pressure, feed rate, and standoff distance on material removal rate throughout abrasive water jet cutting of carbon steel metal workpieces. The material removal rate was assessed using a precision balance device by performing sixteen experiments to identify the ratio of weight loss to total cutting time. The Taguchi method was introduced to implement the experiments and indicate the most influential process parameters on material removal rate. The experimental results showed that feed rate and pressure jet had the most effect on material removal rate. The best material removal rate value was 3.71 g/min at jet pressure 300 MPa, feed rate 30 mm/min, and standoff distance 4mm.
Engineering and Technology Journal, 2020
In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental F... more In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.
Engineering and Technology Journal, 2020
The Electro discharge machine that named (EDM) is used to remove the metal from the workpiece by ... more The Electro discharge machine that named (EDM) is used to remove the metal from the workpiece by spark erosion. The work of this machining depends on the multiple variables. One of the most influential variants of this machine is the polarity, the material of the electrode, the current and the time pulses. Essentially the polarity of the tool (electrode) positive and the work piece is negative, this polarity can be reversed in this paper was reversed the polarity that was made the tool (electrode) negative and the work piece was positive. The aim of this paper was focused on the influence of reversed the polarity (negative) with changing the electrode metal (copper and graphite) on the surface roughness and metal removal rate by using different parameters (current and pulses of time). Experiments show that: the copper electrode gives (best surface roughness 0.46 µm when the current 5 Am and Ton 5.5 µs) and (worst surface roughness 1.66 µm when the current is 8 A and Ton 25 µs). And...
University of Technology, Baghdad, IRAQ
In this study the authors attempt to present a climatology of the cut-off low systems (COLs) for ... more In this study the authors attempt to present a climatology of the cut-off low systems (COLs) for the Greater European Alpine region (GAR). The presented climatology is based on an algorithm which uses physically based criteria to detect COLs in the European Center for Medium-Range Weather Forecasts reanalysis ERA-40 dataset. Moreover, an in depth analysis is carried out to understand the relationship between COLs and extreme precipitation events which can affect large areas (~75 sq. km is considered) in the GAR. This is achieved by coupling the algorithm with the Swiss Federal Institute of Technology Zurich precipitation dataset. The presented analysis also highlights the relevance and importance of COLs in manifestation of Alpine extreme precipitation events.
IOP Conference Series: Materials Science and Engineering, 2021
The present paper focuses on the wire electrical discharge machining (WEDM) of titanium alloys. I... more The present paper focuses on the wire electrical discharge machining (WEDM) of titanium alloys. It can be considered as an attempt to develop two dielectrics in the WEDM significantly affects the efficiency of machining. This paper explores surface ruggedness during the processing of titanium of various dielectric fluids, including demineralized water and dielectric alumina. The findings show that dielectric alumina as a dielectric produces decreased ruggedness on the surface. Also, surface rudeness is better for demineralized water as the dielectric powder is mixed with non-conductive alumina powder. Many dielectric liquids show that surface ruggedness decreases. Alumina powder and ethylene glycol to dielectric water. A comparative surface roughness analysis for different dielectric fluids was also performed. Using surface roughness to analyze surface roughness is further studied. Conducting a further investigation to use the response surface method (RSM) on surface integrity in ea...
˜Al-œKhawarizmi engineering journal, 2015
Experimental work from Magnetic Abrasive Finishing (MAF) tests was carried out design parameters ... more Experimental work from Magnetic Abrasive Finishing (MAF) tests was carried out design parameters (amplitude, and number of cycle which are formed the shape of electromagnetic pole), and technological parameters (current, cutting speed, working gap, and finishing time) all have an influence on the mechanical properties of the surface layer in MAF process. This research has made to study the effect of design and technological parameters on the surface roughness (Ra), micro hardness (Hv) and material removal (MR) in working zone. A set of experimental tests has been planned using response surface methodology according to Taguchi matrix (36) with three levels and six factors. The analysis of variance and instruction curves indicate some significant. X1; X4; X6 have a significant effect on the surface roughness Ra for steel, X2 has mildly significant, while X3 and X5 have insignificant effect. The results showed that roughness of workpiece decreased from 0.3 to 0.15 µm that means improve...
Electrochemical Machining (ECM) is a relatively important method of removing metal by anodic diss... more Electrochemical Machining (ECM) is a relatively important method of removing metal by anodic dissolution. In this research the ECM was used to remove the metals from the internal hole of the workpiece.The tool used was made from brass. This research focuses on the parameters of the change in gap size, the change in current density, and the change of the tool roughness on the Material Removal Rate (MRR), and Surface Roughness of the workpiece. The Statistical Package for Social Science (SPSS) software was used to predict the results. It was found that for the surface roughness the coefficient of determination of the prediction was (0.982) and the accuracy of prediction (97.15%). For the Material Removal Rate in (g/sec) units the coefficient of determination of predicts was (0.991) with accuracy of prediction (98.29%).
2019 Southern African Universities Power Engineering Conference/Robotics and Mechatronics/Pattern Recognition Association of South Africa (SAUPEC/RobMech/PRASA), 2019
Due to kinematic, physical, or operational constraints in terrain types, it is necessary for a mo... more Due to kinematic, physical, or operational constraints in terrain types, it is necessary for a mobile robot to be able to quantify the traversability characteristics of its environment to ensure safe and efficient navigation. The Gaussian Process Regression approach is a supervised method which promises to add completeness to one of the aspects of traversability analyses, namely environment modelling. This paper presents experimental results which demonstrate the effectiveness of Gaussian Process Regression in predicting the values of missing data for artificial environment features as well as actual collected point cloud data. The study concludes that when there are sufficient points the regression fits more closely to the features in the data set, with less error. Also, the prediction model produced by the Gaussian Process Regression method can be useful during robot operation to improve the terrain modelling.
Engineering and Technology Journal
Electrical discharge machining (EDM) is one of the most common non-traditional processes for the ... more Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.
Engineering and Technology Journal
Discharge Machining is a non-traditional machining technique and usually applied for hard metals ... more Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The...
Engineering and Technology Journal
Increase the demand to produce complex shapes with high quality and dimensional accuracy such as ... more Increase the demand to produce complex shapes with high quality and dimensional accuracy such as production aerospace, cars, die sinking has been leading to increase the demand to use the non- traditional cutting operations such as wire electro-discharge machine (WEDM) rather than using the traditional operations. An idea to understand the effect of wire diameter, wire feed, pulsing (on/off) time on surface roughness, and metal removal rate of Cr-Mo steel during wire electrical discharge machining was investigated. Two Steel alloy samples with dimensions of (60 x50 x 20)mm were cut into four rectangular spaces with (5x10x20)mm at one side of each sample using wire cut (EDM) machine with a wire diameter of 0.25 mm and feeding rate 2 m/min for sample 1 and a 0.3 mm diameter and 3 m/min feeding rate for sample 2. Pulse (on, off) time was (110, 50), (112, 52), (115, 55), (116, 57) corresponds to space 1, space 2, space 3, and space 4 in both steel block. Surface roughness and metal remo...
IOP Conference Series: Materials Science and Engineering
2ND INTERNATIONAL CONFERENCE ON MATERIALS ENGINEERING & SCIENCE (IConMEAS 2019)
Engineering and Technology Journal
The presented study has the aim of finding out the relationships between input variables and proc... more The presented study has the aim of finding out the relationships between input variables and process parameters that describe mathematical models, also to estimate the impact of independent parameters on the Heat Affected Zone (HAZ). In the presented paper, A2-Tool Steel material is the utilized workpiece material, whereas copper is the electrode material. RSM, which is the abbreviation of Response Surface Methodology, is used for identifying the impact of controllable parameters; such controllable effects consist of pulse current, pulse on time, and pulse off time on HAZ. It has been noticed that model has been developed by RSM adequacy is suitable since the coefficient related to the determination is considered closest to one for HAZ, whereas the highest percentage of error between experimental and predicted data is (-13.829%). From ANOVA, the pulse current has the most significant factor affected on HAZ with 67.219% contribution.
Diyala Journal of Engineering Sciences
This paper focuses on intervening variables in wire cut process such as pulse on time, pulse off ... more This paper focuses on intervening variables in wire cut process such as pulse on time, pulse off time, voltage, type of wire which use in experiments, it finds that all values from experiments to use in statistical package of social science model. The R square pieces are (0.998). Also they Show that 99.8% of the observed variability in material removal rate can explain by the independent variables. The multiple R is 0.999 for coat wire. This means that the correlation coefficient between the observed value of the dependent variable and the predicted value base on the regression model which are high as this means that the statistical model could predict. The Ra with about 98.7 % and 96.8 % accuracy of the testing data set for coat wire respectively. 1-INTRODUCTION Wire EDM has introduced in the late 1960s', and has revolutionized the tool and die, mold, and metal working industries. It has probably the most exciting and diversified machine tool to develop for this industry in the last fifty years, and has numerous advantages to offer. It can machine anything that has electrically conductive regardless of the hardness, from relatively common materials such as tool steel, aluminum, copper, and graphite, to exotic space-age alloys including in conel, titanium, carbide, polycrystalline diamond compacts and conductive ceramics [1]. Wire cut process has one of thermal nontraditional machining which has important applications and most widely in different industries, electrical discharge machining which has based on the principle of removing material by repeated electrical discharges between the tool termed as electrode and the workpiece in the presence of a dielectric fluid [2].The wire has not touch the workpiece, so there has no physical pressure imparted on the workpiece compared to grinding wheels and milling cutters[3]. The amount of clamping pressure has required to hold small, thin and fragile parts have minimal, preventing damage or distortion to the workpiece. The accuracy, surface finish and time have required to complete a job which have extremely predictable, making it much easier to quote, EDM leaves a totally random pattern on the surface as compared to tooling marks left by milling cutters and grinding wheels. The EDM process have leave no residual burrs on the workpiece, which have reduced or eliminates the need for subsequent finishing operations [4]. Wire EDM has also given designers more latitude in designing dies, and management more control of manufacturing, since the machining has completed automatically [5]. Parts have complex geometry and tolerances has not required you to rely on different skill levels or multiple equipments. Substantial has increased in productivity which has achieved, since the machining has untended, allowing operators to do work in other areas. Most machines have run overnight in a "lights-out" environment [6]. Long jobs have cutten overnight, or over the weekend, while shorter jobs have scheduled during the day. Most workpieces have comen off the machine as a finished part, without the need for secondary operations. It's a one-step process[5] .today has important applications in manufacturing solar cells which led to high Diyala Journal of Engineering Sciences EXPERIMENTAL INVESTIGATION TO PREDICT METAL REMOVAL AND SURFACE ROUGHNESS IN WIRE CUT PROCESS
IOP Conference Series: Materials Science and Engineering
The present work is aimed to improve the thermal effects of electrical discharge machining (EDM) ... more The present work is aimed to improve the thermal effects of electrical discharge machining (EDM) by EDM/ECM hybrid process. A hybrid method of EDM-ECM combined processing involve EDM shaping as well as electrochemical machining (ECM) finishing, also, they are conducted in sequence one same machine tool, same electrode, yet on the different dielectric. Concerning the process of EDM, the material will be removed via the vaporization and melting throughout all electric discharges. Thus, thermally damaged layers make the machined surface. In this study, the used workpiece material is the A2-Tool Steel material, while the electrode material is copper. The influence of controllable parameters could be identified via RSM, which is an abbreviation for Response surface methodology, these controllable effects include: pulse current, pulse on time, pulse off time, gap, voltage, and electrolyte concentration on white layer thickness (WLT) and Surface Roughness (SR). It has been noticed that mod...
Engineering and Technology Journal
Electro discharge machining (EDM) is one of non-traditional machining processes which is used in ... more Electro discharge machining (EDM) is one of non-traditional machining processes which is used in important application. This paper has focused on improving material removal rate by adding powders (Al 2 O 3 particle size 15-35m) and (SiO 2 particle size 20-30m) to kerosene solution through EDM process with different ratios (0.1, 0.14, 0.18 to 0.25 g) particle size for each liter using different values of currents (8, 16 and 30 Amp) and (140 Volt) and (Toff, Ton 25 and 37 μSec), Medium carbon steel is used as a workpeice and copper as electrode, the material removal rate (MRR). It has been found that maximum MRR was (0.2969) g/min when adding SiO 2 powder (0.25)g/l and maximum MRR was (0.2781)g/min when adding Al 2 O 3 powder (0.25)g/l, the Minitab model program was used to predict the MRR which gives a good result and agreement with experiments 99%.
Research gate, 2020
Mechanical errors today occupies an important and large area in the industry because of its impac... more Mechanical errors today occupies an important and large area in the industry because of its impact on the accuracy of mechanically operated products.