Abstract
The present paper studies different types of errors generated on the feature (cylindrical holes) which was fabricated by the wire EDM of 2205 duplex stainless steel. Different experimental parameters such as, pulse on time, pulse off time and wire tension on the feature as well as the contribution of these parameters on cylindricity error, circularity error and diameter error were explored. Moreover, interactions among the input parameters were also considered. It was found that the total contributions of interactions between different parameters are reasonably high for all the cases which make the modelling process very complex for cylindricity, circularity and diameter errors in term of the range of parameter considered in this investigation. Wire tension has highest contribution on cylindricity error which is lowest at high value wire tension. Pulse on time has minor contribution on the cylindricity error and it increases with the increase of pulse on time. Pulse of time does not have any influence on the cylindricity error. The circularity error was lowest at medium pulse off time and medium wire tension; and those two parameters have almost similar and highest contributions. The pulse on time has around 14% contribution on circularity error and the medium value of it minimizes the circularity error. The input parameters such has pulse on time, pulse off time and wire tension have around 13%, 16% and 7% contributions respectively on diameter error which is minimized at medium pulse on time, and low pulse off time and low wire tension.
Highlights
Stainless steel is a renowned engineering material for number of structural applications
Wire electrical discharge machining (EDM) of duplex 2205 stainless steel was investigated by generating cylindrical holes at different machining conditions
The contribution of all interactions is significantly high compare to that of individual parameters for all the cases which indicates that the modelling of the cylindricity, circularity and diameter errors in terms of pulse on time, pulse of time and wire tension for the range of parameter considered in this investigation is very complex. (b) The tension in wire influences the distortion and rigidity of wire electrode where the lesser tension induces higher flexibility
Summary
Stainless steel is a renowned engineering material for number of structural applications. In general, put an extra challenge during machining operation because of high affinity towards work harden; high toughness and comparatively low thermal conductivity and high fracture toughness (Dolinšek, 2003; Jiang, Paro, Hänninen, Kauppinen, & Oraskari, 1996; O’Sullivan & Cotterell, 2002; Paro, Hänninen, & Kauppinen, 2001) These enhanced material properties upsurge tool/chip interface temperature which causes poor surface finish and frequent breaking of chips. Duplex stainless steel has a tendency for built-up edge (BUE) formation which reduces machining efficiency due to material adherence to cutting tool and eventually reduce cutting speeds These result in poor surface finish, low dimensional accuracy and accelerated tool wear (J Nomani, Pramanik, Hilditch, & Littlefair, 2016, 2017). The frequent BUE formation is due to the fact that, materials with two phases experience additional fracture along chip-tool rake face whereas single phase materials retain one fracture point only (Williams & Rollason, 1970)
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