Current Research Trends in Wire Electrical Discharge Machining (WEDM): A Review (original) (raw)
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Perspective and Prospects of Wire Electric Discharge Machining (WEDM)
Journal of Engineering and Technological Sciences
Wire Electric Discharge Machining (WEDM) is a non-traditional machining method that is widely used in the manufacture of aerospace/aircraft and medical equipment for conductive materials. WEDM products are expected to have good dimensional accuracy, surface roughness, and geometry. Many researchers have done experiments on various materials to optimize the process, which has many parameters and response characteristics. This paper provides an overview of the WEDM process on alloy steels in order to understand the impact of input process variables on output responses and optimization techniques for selecting optimal process parameters. This paper also highlights WEDM process trends as well as workpiece materials, wire varieties, wire diameters, and optimization approaches. This work is expected to be useful in initiating further research on WEDM by documenting substantial research works confirming the latest scenario.
Review on Current Research Trends in Wire Electrical Discharge Machining (WEDM)
Indian Journal of Science and Technology
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters , include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Furthermore, different types of WEDM methods introduced and discussed. In addition the paper highlights different modelling and optimization methods and discussed their advantage and disadvantage. The final part of the paper includes some recommendations about the trends for future WEDM researches.
An Overview on Process Parameters Improvement in Wire Electrical Discharge Machining
The dimensional accuracy and quality of the surface of the machined piece are greatly influenced by the determination of optimal range of the Wire-Cut Electric Discharge Machining (WEDM) Parameters. Numerous researchers have approached to solve this problem with experimental, analytical and numerical analysis. There is less work of the consensus on the basic effect of the Wire material on the workpiece in WEDM, even though considerable research effort has been made on it. It is staggeringly difficult to foretell in a precise manner the performance of Wire in WEDM for the dimensional accuracy and quality of the surface machined from this process. This paper reviews work on the requirements for optimization of Tool wear so that its life could easily be predicted.
STUDY OF PROCESS PARAMETER OF WIRE ELECTRIC DISCHARGE MACHINING: THE REVIEW
Wire EDM is a variation of the Electric Discharge Machining and is commonly known as wire-cut EDM. In WEDM, material is eroded from the work material by a series of discrete sparks occurring between the work piece and the wire which is generally act as electrode, separated by a stream of dielectric fluid. Dielectric fluid commonly used is deionized water which is act as coolant and flushes the debris away. Work piece is generally electric conductive. It can machine anything that is electrically conductive regardless of the hardness, from relatively common materials such as tool steel, aluminum, copper, and graphite, to exotic space-age alloys including Inconel, titanium, carbide, polycrystalline diamond compacts and conductive ceramics. This papers shows the detailed analysis of process parameters
Review on Wire Electrical Discharge Machining of Die and Tool Grade Steels
Wire Electrical Discharge Machining is one of the most prominent and widely used Non-Traditional machining processes. This Wire-EDM is primarily used for cutting of complex and intricate profiles in the materials having varying hardness and more importantly due to its indispensable qualities like higher dimensional accuracy and precision of the machined components which are highly desirable in the machining industries. Wire EDM effectuates a plasma channel in-between the anode and cathode by using the electrical energy and converts it into thermal energy capable of producing 8000 – 12,000 °C temperature. This paper reviews the works carried out in wire electrical discharge machining of die and tool grade steels. The die steels are utilised in manufacturing of forging dies, die-casting, die blocks, and drawing dies etc. This paper addresses the different methodologies adopted, optimisation techniques employed and various input parameters chosen along with their focussed output parameters and the effect of these input parameters on the results obtained. This paper also reviews the research contributed to achieve fine surface finish during machining and controlling the breakage of wire or earlier detection and indication of wire breakage. Finally the paper puts forth some recommendations for future research scopes in the machining of die steels using Wire EDM.
A review on the state of art in Wire Electric Discharge Machining
2011
Electrical discharge wire cutting, more commonly known as wire electrical discharge machining (WEDM), is a spark erosion process used to produce complex two-and three-dimensional shapes through electrically conductive work pieces by using wire electrode. The sparks will be generated between the work piece and a wire electrode flushed with or immersed in a dielectric fluid. The degree of accuracy of work piece dimensions obtainable and the fine surface finishes make WEDM particularly valuable for applications involving manufacture of stamping dies, extrusion dies and prototype parts. The most important performance measures in WEDM are MRR (or cutting speed), surface roughness and kerf (cutting width). Discharge current, discharge capacitance, pulse duration, pulse frequency, wire speed, wire tension, average working voltage and dielectric flushing conditions are the machining parameters which affect the performance measures. Over the years, the WEDM process has remained as a competitive and economical machining option fulfilling the demanding machining requirements imposed by the short product development cycles and the growing cost pressures. However, the risk of wire breakage and bending has undermined the full potential of the process drastically reducing the efficiency and accuracy of the WEDM operation. A significant amount of research has explored the different methodologies of achieving the ultimate WEDM goals of optimizing the numerous process parameters analytically with the total elimination of the wire breakages thereby also improving the overall machining reliability. This paper reviews the vast array of research work carried out from the spin-off from the EDM process to the development of the WEDM. It reports on the WEDM research involving the optimization of the process parameters surveying the influence of the various factors affecting the machining performance and productivity.
Materials Today: Proceedings, 2018
Wire electric discharge machining (WEDM) is an advance manufacturing process for machining hard materials. The machining efficiency and productivity of WEDM not only depends on machining parameters but also improved by proper selection of electrode material. In this investigation brass wire and silver coated brass wire are selected as electrode material to evaluate the influence of wire material on WEDM machining performances. From analysis of variance, it was reveals that pulse on time, servo voltage is one of the dominant parameters. Machining with silver coated brass wire found to be best alternative of brass wire on the Maraging steel 300.
2016
Wire electrical discharge machining (WEDM) is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). WEDM involves high cutting rates and superior quality to improve machining performance in manufacturing hard materials. The machining performance of computer-controlled WEDM is directly dependent on spark energy (pulse on time, peak current, and gap voltage), pulse frequency (pulse off time and pulse on time), and wire electrode parameters (material, wire speed, and wire tension). In the field of wire electrical discharge machining, it is necessary to develop suitable WEDM technology to facilitate the production of high quality workpiece surfaces at high cutting rates. Surface roughness and white layer thickness are the most important factors in evaluating WEDM surface quality. In order to ensure good surface quality, the surface roughness must be low and the white layer must be as thin as possible, homogeneous, crack-free, and well-bonded t...
Characterization of Wire Electric Discharge Machining of AISI 1040 Steel
Wire electrical discharge machining (WEDM) is an important non-traditional machining process, widely used in aerospace, nuclear, electronics, medical and automotive industries. AISI 1040 material used in automotive for manufacture of forged arm rod. In this work WEDM process is used to machine AISI 1040 steel. Pulse on time, pulse off time, wire feed and current were taken as input parameter. The effect of these input parameters on material removal rate (MRR), machining speed and machining time is analyzed. MRR increases with increase in pulse on time, wire feed and current whereas MRR decreases with increase in pulse off time.
Jurnal Teknologi, 2015
The purpose of this project is to study the encouragement of three machining parameters on wire electrical discharge machining that consist of peak current (IP), pulse OFF time (OFF) and wire tension (WT) to three machining responses which are cutting rate (CR), material removal rate (MRR) and surface roughness (SR) on high carbon steel (S50C). Brass wire with diameter 0.25 mm was used as the cutting tool for machining a high carbon steel (S50C) using Mitsubishi FX Wire Electrical Discharge Machine (WEDM). The machining parameters such as pulse off time, wire tension and peak current were determined by referring from the guideline in the manual book for Mitsubishi FX Wire Electrical Discharge Machine (WEDM). The calculation of material removal rate and cutting rate were obtained using mathematical equation. The surface roughness was measured using optical measurement “Alicona Infinite Focus” machine. The relationship between material removal rate and surface roughness shows that the...