Abstract
The experimental study is about the optimizing the cutting process parameters of the WEDM (Wirecut Electric Discharge Machining) during the machining of Titanium Ti 6Al-4V (Grade 5) material. The high strength and high hardness of Titanium Ti 6Al-4V (Grade 5) alloy offers a challenging task in obtaining a better surface finish and Material Removal Rate. The material removal rate and the surface roughness of Titanium Ti 6Al-4V (Grade 5) is carried out and an excellent machined surface can be obtained by the setting the machining parameters at optimum level by various experimental study of material while machining in WEDM. The machining parameters such as Pulse ON time (TON), Pulse OFF time (TOFF), Gap Voltage (GV) and Wire Feed Rate (WFR) used as input parameters to attain optimum output responses like Material Removal Rate(MRR) and surface roughness using Taguchi’s DOE approach. In this present work, 9 Experiments were conducted for 4 inputs Parameter and 3 levels for each Input parameter and the experimental results of MRR were analysed using Taguchi method. From the Signal to Noise ratio values of MRR, the optimum levels of selected Input Process Parameter were found successfully
Highlights
Accompanying the development of aerospace materials, the demands for alloy materials having high hardness, toughness and impact resistance are increasing
wire cut Electrical Discharge Machine (WEDM) process with a tinny brass wire as an electrode transformed as thermal energy from electrical energy for cutting materials
Since the low kerf and the high Material removal rate (MRR) are important goals in WEDM, equal machine feed rate are recommended
Summary
Accompanying the development of aerospace materials, the demands for alloy materials having high hardness, toughness and impact resistance are increasing. The effects of various control factors of WEDM have been investigated for optimizing surface roughness while machining cryogenic treated D-3 material. Muthu Kumar et al (2010) reported an application of both Taguchi and Grey Relational Taguchi Analysis, to improve the multiresponse characteristics on Material Removal Rate, Surface roughness in WEDM of super-alloy Incoloy 800 As a result, this method greatly streamlines the optimization of complex multiple performance characteristics. Experimental determination about the effects of the various process parameters viz pulse on time, pulse off time, spark gap set voltage, peak current, wire feed and wire tension on the performance measures like cutting rate, surface roughness, gap current and dimensional deviation in WEDM process is to be enumerated. To improve the output responses such as MRR & SR with respect to the input process parameters such as TON, TOFF, WFR, GV while machining Ti on WEDM by Taguchi method.[13-15]
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