Study the impact of process parameters and electrode material on wire electric discharge machining performances (original) (raw)
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Optimization of Machining Parameters on Wire Electric Discharge Machining of Maraging Steels C300
International Journal for Research in Applied Science and Engineering Technology -IJRASET, 2020
Electric discharge machining (EDM) is categorized under thermoelectric process in which heat energy of spark is used to remove the material from work piece. This process involves controlled deterioration of electrically conducting material by the initiation of rapid and repetitive electrical spark discharges among tool and work piece, which are divided by dielectric. The present thesis aimed that is to characterizing the wire electric discharge machining parameters of maraging steels 300 on WEDM by using Molybdenum as a wire. The total of 18 experiments are conducted (9holes and 9 slots.).The Machining is executed by varying WEDM cutting parameters such as pulse off time, current and pulse on time. The outputs are measured like material removal rate and surface finish are assessed. It is found that metal removal rate is increasing with increasing with current and pulse on time. Surface finish is also increases with increasing in current. As the pulse on time goes on increasing the material removal rate increases but surfaces finish increases slightly. As the current value increases from 2 to 4amps the MRR is increasing by gradually, but SF is increased significantly
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
In this research paper, the different process parameters of wire cut electrical discharge machining process are studied. And work piece material for which parameters are to be optimized is H 13 Hot die tool steel material with a 0.25 mm coated wire by using Taguchi methodology. The selection of machining parameters in any machining process significantly affects surface finish, production rate and production cost of a finished one component. The experiment has been formulated with the help of Design of experiment and grey relational analysis. The Taguchi method is used to formulate the experimental layout, to analyse the effect of each parameter on the machining characteristics, and to predict the optimal choice for each WEDM parameter. Experimentation is planned as per Taguchi's L8 Orthogonal Array (OR).In this experiment optimize the input process parameters Pulse on time (T ON), Pulse off time (T OFF), peak current (IP), Wire feed rate (WF), Wire tension (WT), Servo voltage (SV) of a WEDM process for a response parameters Surface Roughness (SR), Material Removal Rate (MRR) and Kerf Width (KW) for a H 13 HOT DIE TOOL STEEL. The experimental results are to be analysed using analysis of variance (ANOVA) to find out significant contribution of machining parameters over response parameters and the optimal combinations of the parameters are to be determined.
Current Research Trends in Wire Electrical Discharge Machining (WEDM): A Review
2018
Wire Electrical Discharge Machine (WEDM), a non-traditional machining process, is becoming more important in providing a non-contact machining process. It is suitable for machining geometrically complex and hard advanced material which is impossible to machine using the conventional machine. This paper reviewed the experimental results on performance evaluation of machining parameters which affected machining performance which would reflect the machining factors and responses. In addition, the methods in analyzing, modelling, development and tool steel in WEDM were also discussed. Some recommendations and future WEDM research were proposed.
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 to the substrate material. In this study, the effect of cutting parameters is investigated on the machining performance parameters including cutting speed, surface roughness, wire rupture, and white layer thickness. The adaptive Neuro-Fuzzy Inference System (ANFIS) along with the Taguchi method is applied to determine the effects of the significant parameters on WEDM performance. Moreover, a new performance index is proposed to identify the effects of spark energy and pulse frequency simultaneously on machining performance and to identify the wire rupture limit. However, the performance index cannot be used to identify the most feasible wire electrode from ecological (energy and wire consumption) and economic (machining costs) perspectives. Therefore, a new performance criterion (production economic index) is developed to select the most feasible wire electrode considering the economic and ecological aspects along with the performance index to achieve superior machining performance at the lowest cost. This can be done by dividing the performance index by the total machining cost ((Es×DF)/Ct). In addition, a new coated-wire electrodeiv design with higher strength for less wire rupture and high machining performance in WEDM is proposed. The results obtained represent a technological knowledge base for the selection of optimal machining conditions along with suitable types of wire electrodes for WEDM in terms of ecological and economic aspects. By applying the proposed performance criterion (Es×DF/Ct), it appears that using lower spark and higher pulse cycle settings with a brass wire electrode can decrease the surface roughness and white layer thickness, and facilitate more economical cutting speed. This could lead to faster cutting with good surface finish and less wire rupture.
The effect of electrode material on machinability in wire electro-discharge machining
Journal of Materials Processing Technology, 1997
Reported in the present paper are the requirements of the materials used for WEDM electrodes that will lead to the improvement of WEDM performance. Experiments have been conducted regarding the choice of suitable wire electrode materials and the influence of the properties of these materials on the machinaNfity in WEDM, the experimental results are presented and discussed.
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.
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...
2013
Presently manufacturing industries are facing various challenges from these advanced materials viz. super alloys, ceramics, and composites, whose mechanical properties are hard and difficult to machine. It requires high precision, surface quality which increases machining cost. To meet these technological challenges, non-conventional machining processes are being employed to achieve higher metal removal rate, better surface finish and greater dimensional accuracy, with less tool wear. Electric Discharge Machining (EDM) is a non-conventional process and has a wide applications in automotive, defense, aerospace and micro systems industries plays an excellent role in the development of cost effective products with more reliable quality assurance. Here we report and analyse the various parameters in Electrical Discharge Machining. Experimental results are discussed on electric discharge machining of OHNS (Oil Hardening non Shrinking Tool Steel) Die material in Copper and Aluminium electrode. Statistical analysis is presented to identify the effect of process input factors (viz. current, voltage) on the output factors viz. Material Removal Rate (MRR), Electrode Wear Rate (EWR). Keyword-Electrical discharge machining (EDM), Material removal rate (MRR), Tool wear rate (TWR), Oil Hardening non Shrinking Tool Steel (OHNS), Percentage of Wear Rate (PWR).