An experimental investigation of F53 super duplex stainless steel using wire cut EDM process

Abstract

This research focuses on the machinability of F53 super duplex stainless steel using the Wire Electrical Discharge Machining (WEDM) process. F53 Super Duplex Stainless Steel is known for its exceptional corrosion resistance and mechanical properties. It is a popular choice for critical applications in various industries, such as offshore, chemical, and petrochemical. The wire EDM process is chosen for its ability to achieve precise and intricate cuts in hard-to-machine materials like super duplex stainless steel. This study considered important process variables like wire feed rate, servo voltage, pulse-on and pulse-off time, and material removal rate and surface roughness as output responses. Box Behnken method is used to analyse all possible interactions between input and output variables are taken into account, and three different levels of parameter conditions are adopted. It was found that MRR increased by 51.30 % with a gradual increase in pulse on time and applied wire feed and SR decreased by 62.86 % gradually with increasing servo voltage and pulse off time. The optimized values are found to be Ton = 11 µs, WF = 13 m/min, SV = 40 V and Toff = 8 µs. The microhardness study confirms the formation of the melted layer on the machined surface. This research contributes to a deeper understanding of the wire EDM process's applicability to the challenging material properties of F53 super duplex stainless steel, offering insights for the manufacturing and engineering industries aiming to improve the efficiency and precision of machining operations for this advanced material.