Abstract
Wire electrical discharge machining is an unconventional machining method for the production of complex-shaped and very precise parts. Because of the high energy consumption of this machining process, it is necessary to maximize the cutting speed for its appropriate implementation. The abrasion-resistant steel Creusabro 4800 was chosen as the test material for this experiment, which is widely used especially for machines working in mines and quarries. In order to maximize the cutting speed, a fuzzy inference system (FIS) has been built, which uses 18 expert propositions to “model” the cutting speed based on five selected input parameters: gap voltage, pulse on time, pulse off time, discharge current, and wire feed. The obtained results were further verified by a design of experiment consisting of 33 tests for five selected input factors. Using the fuzzy inference system, the optimum machine parameters setup was found to maximize the cutting speed, in which the gap voltage = 60 V, pulse on time = 10 µs, pulse off time = 30 µs, wire feed = 10 m∙min−1 and discharge current = 35 A. The predicted value of the cutting speed using the fuzzy inference system is 6.471 mm∙min−1.
Highlights
Wire electrical discharge machining (WEDM) is a widely used technology in the automotive, aerospace, military, and medical industries
The purpose of this study is to find the setup of machine parameters that maximize the cutting speed of the widely used wear-resistant steel Creusabro
Based on the expert’s knowledge, 18 propositional formulas were constructed, which were the basis of the fuzzy inference system of the cutting speed model for WEDM of the abrasion-resistant steel Creusabro 4800, and the following conclusions were reached
Summary
Wire electrical discharge machining (WEDM) is a widely used technology in the automotive, aerospace, military, and medical industries. It is an unconventional machining technology that uses a thermoelectric principle to cut the material. There are no requirements on the machined material in terms of mechanical properties, only it must be at least electrically conductive [1,2]. WEDM is generally perceived as an energy-intensive machining technology, maximizing the cutting speed is a key parameter in terms of process optimization [3,4]. High abrasion-resistant steels such as Creusabro are used, thanks to their unique mechanical properties, for a variety of machines or in mines and quarries for scrap metal processing machines [5]. Zadeh laid the foundations of this branch of mathematics in 1965 [7]
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