WEDM Process Parameters Research Articles

WEDM Process Parameters Analysis and Optimization: A Review

WEDM Process Parameters Analysis and Optimization: A Review

Experimental Investigation and Optimization of WEDM Process Parameters for the Development of Ni-Based Hardfaced Turning Tool Insert Using Hybrid GA-CoCoSo Technique

Experimental Investigation and Optimization of WEDM Process Parameters for the Development of Ni-Based Hardfaced Turning Tool Insert Using Hybrid GA-CoCoSo Technique

Experimental investigation of productivity and surface integrity features in trim cut WEDM operation of hybrid metal matrix composite

Present study is focused on optimization of WEDM process parameters for increased productivity and improved surface quality of the machined surface of hybrid composite [Al6061 (90 %), SiC (2.5 %) and TiB2 (7.5 %)] by utilizing the trim cut strategy. Effects of four factors namely, pulse on time (Ton), peak current (Ip), wire offset (WO) and rough-cut history (RCH) have been investigated on response characteristics namely, material removal rate (MRR), surface roughness (SR) and Recast layer (RL) thickness; using Box-Behnken design (BBD) for the experimentation. Three levels of RCH i.e., high, medium and low have been included to investigate the effectiveness of trim cut strategy for dealing with rough-cut surface under varied conditions. The optimized parametric setting has been obtained for multiple responses using desirability function. RCH is found to be most significant factor for MRR, while pulse on time (Ton) is found most significant for SR and RL. WO has been found to play an important role in controlling the thickness of RL. It is observed that after trim cut, surface roughness is improved for experiments conducted under high and medium levels of RCH. However, almost no improvement in SR is obtained for low level of RCH. Trim cut strategy is also found to be effective in reducing the thickness of recast layer, however, it is noticed that the percentage reduction in recast layer thickness for samples machined under high level RCH is greater than that for the other two levels of RCH.

Evaluation of response characteristics using sensitivity analysis and TLBO technique of powder mixed wire EDM of Ti6Al4V alloy

The development of Powder Mixed Wire Electric Discharge Machining (PMWEDM) aims to enhance both precise dimension and surface quality, making it a more efficient method for the cost-effective production of precise dies and tools compared to conventional Wire Electric Discharge Machining (WEDM. This approach effectively eliminates the need for secondary operations. The present study is focused on the parametric influence of surfactant with powder mixed WEDM process parameters during die corner cutting on Ti6Al4V material in the presence of surfactant and powder with dielectric. A sensitivity analysis was conducted to determine the significant influence of machining parameters and powder properties in conjunction with the dielectric. To empirically explore these variables, a central composite full factorial design based on response surface methodology was utilized. The design involved varying the pulse on-time (Ton) within the range of 30–90 µs, pulse off-time (Toff) within 3–11 µs, gap voltage (GV) within 40–80 V, and powder concentration (PC) within 2–10 g/L. The mathematical model was developed to predict the responses such as corner inaccuracy (CI) and surface roughness (SR) using RSM. The results conclude that the sensitiveness of powder concentration is highest. Apart from this, positive sensitiveness towards surface roughness is determined for three inputs: pulse on time, pulse off time, and powder concentration. In comparison, powder concentration shows positive sensitiveness towards corner inaccuracy. An artificial intelligence technique namely, Teaching learning-based optimization (TLBO) algorithm has been used to determine the best output. The minimum output for both responses, i.e. corner inaccuracy of 12982.67 µm2 and surface roughness of 1.199 µm, was obtained using TLBO technique. Further improvement for surface finish and corner accuracy in addition powder (3 g/L) with dielectric in WEDM process is found to be a value of 50.77% and 23.01%, respectively, compared with conventional WEDM process. SEM was employed to observe and analyze the topographical changes that occurred during powder mixed and without powder mixed in WEDM process.

Study on mechanical properties of AMMC and optimization of WEDM process parameters

Study on mechanical properties of AMMC and optimization of WEDM process parameters

EXPERIMENTAL INVESTIGATION AND OPTIMIZATION OF MACHINING PARAMETERS IN WEDM OF ZrO2 AND SEASHELL POWDER-REINFORCED BIODEGRADABLE AZ31 Mg ALLOY COMPOSITE

In the current scenario, many researchers aspire to develop biodegradable material for biomedical implant applications. Magnesium (Mg)-based alloys are most promising materials since they have mechanical properties similar to human bone. In this study, Mg alloy AZ31 matrix was reinforced with a seashell powder (2[Formula: see text]wt.%) and zirconium dioxide (10[Formula: see text]wt.%) using bottom pouring stir casting furnace. Scanning electron microscope (SEM) with energy dispersive spectroscopy (EDS) images confirms the proper distribution of reinforcement throughout the matrix. This study analyzed the influence of WEDM process parameters for the material removal rate (MRR) and surface roughness (SR) of the proposed composite. According to Taguchi’s L9 (3[Formula: see text] orthogonal array the machining was performed to investigate the ideal machining parameters with a range of pulse current (I[Formula: see text] 6–8 amps, pulse-on time ([Formula: see text]) 5–15[Formula: see text][Formula: see text]s and pulse-off time ([Formula: see text] 10–30[Formula: see text][Formula: see text]s, respectively. Analysis of variance (ANOVA) result confirms that [Formula: see text] (45.86%) has the most influencing parameter affecting the MRR and SR, followed by [Formula: see text] (25.10%) and [Formula: see text] (17.19%), respectively. Furthermore, Technique for Order Preference by Similar Ideal Solution (TOPSIS) and desirability approach was employed to find the optimal parameter combinations to attain the best combined output responses.

Process optimization of WEDM D2 steel based on orthogonal test and response surface method

Abstract D2 steel can be used to manufacture cold working molds with large cross sections, complex shapes, high impact forces and high wear resistance requirements. Cutting speed is an important process index of WEDM. In order to study the influence of WEDM process parameters on the cutting speed of D2 die steel and explore the process parameters at the maximum cutting speed, In this experiment, the electrical parameters pulse width, pulse interval and servo voltage were selected as test factors, and the cutting speed process indexes were analyzed and optimized by orthogonal test and response surface analysis method. Experimental results show that: the influence of main electrical parameters on cutting speed is consistent; the effects of pulse width, pulse interval and servo voltage on cutting speed decrease successively; the optimum process parameters obtained after optimization are consistent, pulse width 8μs, pulse interval 10μs, servo voltage 38V.

A RSM based MOGOA for process optimization during WEDM of Inconel 625

Inconel 625 is a super alloy that has excellent thermal and mechanical properties but is arduous to machine with conventional machining processes due to high melting point and hardness. Wire Electro Discharge machining, that have been an avowed unconventional process of machining that is mainly applied for the machining of tough and hard materials such as Inconel 625. An attempt, in this article, have been made to optimize the WEDM process parameters like servo voltage, peak current, spark-on time, spark-off time while machining on Inconel 625. The study considers Material Removal Rate (MRR) and Surface Roughness (SR) as performance parameters of machining process. L16 orthogonal array is implemented to design the experiments. Mathematical relations between the response parameters and the input variables are computed using of Response Surface Methodology (RSM). The mathematical models are then employed as a fitness function in the Multi-objective Grasshopper Optimization Algorithm (MOGOA) for determining optimal process parameters. Later, a comparison of MOGOA has been done with Non-dominated Sorting Genetic Algorithm II (NSGA- II) and Multiple Objective Particle Swarm Optimization (MOPSO) and found superior to both. Also, for responses like surface roughness (SR) and material removal rate (MRR), the predicted values in the present study are found to be in good proximity to the experimented values.

Swirl cast with wire cut electric discharge machining for investigational purposes on Al-7075/Al2O3&SiC

The real applications of aluminium metal matrix composites encompass aerospace, armed services, automotive, aerobics instruction equipment, and electronics, and many are esteemed for innovative complementary properties such as illumination mass, enhanced effectiveness, and coefficient of thermal extension. The feasible Al 7075 alloy is widely used in aerospace manufacturing constituents in terms of structural mechanism incremental improvement. Throughout this preliminary investigation, Al-7075 was toughened amid rising 2, 4, 6, and 8 influence support in expressions of entitlement to Al203 and 3 influence support in expressions of proportionality of SiC, being genuine and genuine man-made, and utilizing the swirl transmission method. Stiffness, elongation, impact, and wear test specimens are positioned in accordance with international standards. The casting process is finished, and up to 8% silicon carbide and aluminium oxide residue will be effectively added to aluminium by using a swirl transmission technique to produce Al-HMC. By enabling the absorption of Al203 and SiC residues, this AL-HMC improved stiffness and tensile strength. When the concentration of Al203 and SiC deposits within the AMC increases, wear and frictional strength decrease. When the percentage of Al203 and SiC in the MMC is significantly increased, the variation in collision intensity becomes minor. The L9 Array in Combination with DOE Techniques this investigation to establish various WEDM process parameters is also enforced into demographic groups with the purpose of improving minimal surface roughness along with MRR for Al7075, Al203, and SiC. It must have been discovered that enhancing the weight percent of Al203 and SiC pilot in addition to increasing surface roughness also reduced MRR. The findings of the study were used to select the fastest and most accurate WEDM Process parameters for attempting to make precision engineering components of HMMC of Al 7075 with Al203 and SiC at various weight percents.

Study on Optimization of WEDM Process Parameters on Stainless Steel

Stainless steel is a material which has high corrosive resistance and oxidation resistance at high temperature with the combination of chromium, nickel, and niobium as a primary constituent. This material which is difficult to machine with complex shape is taken by using wire cut electric discharge machining. Wire electrical discharge machining is a nontraditional process widely taken for cutting and machining for complex shapes. This review paper involves wire cut EDM optimization parameters. Pulse interval, pulse duration, wire feed, voltage, and mean current are the operational parameters. The Taguchi orthogonal array method, analysis of variance (ANOVA), and grey relation analysis (GRA) methods are taken for different kinds of machining various kinds of materials, and different kinds of result with best material removal rate (MRR) and surface roughness (SR) are analyzed. This work suggests the most influencing process parameters and best optimization method for various steel materials.

Wire Electrical Discharge Machining (WEDM) of Hybrid Composites (Al-Si12/B4C/Fly Ash)

The present study looks into the effect of WEDM process parameters on the material removal rate (MRR) and surface roughness (SR) responses when machining hybrid composites (Al-Si12/boron carbide/fly ash) using the Taguchi technique. Fly ash and boron carbide (B4C) particles were used for reinforcement (3%, 6%, and 9% by weight), and aluminium alloy (Al-Si12) was used as a matrix material. ANOVA was used to find out the importance of machining factors that affect the quality features of the WEDM process, as well as the relative role of input parameters in determining the WEDM process’ responses. The greatest impact on the response is finalised by the signal-to-noise (S/N) ratio response analysis. However, as a last step, a confirmation experiment with the best combination was carried out to predict and validate the accuracy of the observed values. As the pulse on time and reinforcement increases, MRR also increases. As the gap voltage, wire feed, and pulse off time decrease, it increases. SR is increased by increasing the gap voltage, pulse on time, and pulse off time, wire feed, and reinforcement. The maximum MRR of 38.01 mm3/min and the minimum SR of 3.24 μm were obtained using optimal machining conditions.

Analysis and optimization of wire Electro-Discharge Machining process parameters for the efficient cutting of Aluminum 5454 alloy

Aluminum 5454 alloys are considered a subject in this research, widely used in the industry, to develop die tools, molds, engine blocks, aircraft structural components, and many other commercial products. In this research, the WEDM process parameters effects on the Aluminum 5454 alloy tapered workpiece have been investigated. Tapered workpieces with angles of 30°, 45° and 60° are prepared, in which slots are generated using the WEDM process. The taper angle, peak discharge current and pulse-off time are selected as the controllable parameters in this research. Whereas other parameters are kept constant. Impact of the parameters over; kerf width, surface finish, MRR and wire have been investigated. ANOVA is applied to statistically analyze the influence of the factors over the four variables. Regression models for the four variables are determined and the Genetic Algorithm is applied to determine the feasible WEDM process parameters for the desirable magnitudes of the four variables. The regression models and optimized parameter values for different taper angles workpieces of Aluminum 5454 alloy can be used in the industry to increase the productivity and enhanced results.

Optimization of WEDM Process Parameters on Surface Roughness and Study of Physical behaviour using SEM for Machining Aluminium Alloy Al 7075 using Brass Coated Copper Wire

Wire Electrical Discharge Machining is one of the most effective Non-Conventional Machining method available to machine intricate shapes which are very difficult to machine with conventional machining methods, on electrically conductive materials havingvarying hardness. In this research work, an attempt hasbeen made to study the effect of process parameters of WEDM on the Surface roughness. Input process parameters considered in this work are Pulse on time (TON), Pulse off time(TOFF), Wire Feed (WF), Wire Tension(WT) and theSurface Roughness as response. Al 7075 Aluminium alloywas taken as work material and Brass coated copper wire as electrode to machine and the values of roughness obtained by varying the input process parameters were analysed using Taguchi method (L 27 orthogonal array). The measured values have been used to develop the mathematical modeland the accuracy of the model wastested using Analysis of Variance (ANOVA) technique. Based on the predicted values the interaction graphs, were drawn betweentheSurface roughnessandthe processparameterstaken for this study. It was construedthatthepulse-on time has the highest impact on the Surface roughness followed by the Wire feed, Wire tension and the Pulse-off time. The surface roughnessgot increasedwith increase in wire feed. Finally optimum parameters have been arrived to achieve better surface roughness. WEDMed surface was also examined by using scanning electron microscope (SEM) and evinced that the physical behaviour of these process parameters on Surface roughness.Copyright © VBRI Press.

Application of MCDM based hybrid optimization of WEDM process parameters

This work investigates the process parameters like peak current, applied voltage, wire feed rate on machining characteristics kerf width and surface roughness of Wire Electrical Discharge Machine (WEDM) while machining AA6351/Rutile composite which is fabricated by powder metallurgy technique. In this experimental work, Taguchi’s L27 orthogonal design is used for conducting experiments. This present research has been intended to optimize the setting of process parameters in order to improve the machining performance by coupling different Multi-Criterion Decision making methods such as Multi-Objective Optimization process on the basis of Ratio Analysis (MOORA) and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) with Principal Component Analysis (PCA). When the hybrid MOORA-PCA and TOPSIS-PCA are applied, the results display with a peak current 12 amps, applied voltage 20 V and wire feed rate 5 m/min. When compared these two hybrid methods, MOORA-PCA approach clearly indicates its significance because of its simplicity. The optimised setting obtained canbe further used to produce high quality micro-channels for heat exchangers and heat sinks.

Optimization of WEDM process parameters for machining of heat treated ASSAB ’88 tool steel using Response surface methodology (RSM)

The effect of servo reference voltage (SRV), peak current (PC), wire feed speed (WFR) and wire tension (WT) on Material Removal Rate (MRR) and Surface Roughness (SR) have been investigated in WEDM of heat treated ASSAB ’88 tool steel. The optimal set of parameters have been obtained using Response Surface Methodology in combination with the central composite full factorial design. Mathematical correlations for MRR and SR have been formed using regression analysis. Total 117 points have been used for get optimal set and 7 solutions have been reported for both MRR and SR. Out of these 7 solution the optimal solution has been judged by plotting the results.

Optimization of WEDM process parameters by RSM in machining of stir cum squeeze cast A413–B4C composites

In this paper, aluminium alloy metal matrix composites were manufactured via stir cum squeeze casting technique owing to their tremendous automotive and aviation applications. The aluminium alloy with 12 weight percentage boron carbide (A413 with 12 wt% B4C) composites was prepared with optimal stir cum squeeze casting parameters like applied squeeze pressure of 140 MPa, 225 °C preheated die temperature and 12 wt% of B4C particles which yielded pore-free fine-grained equally distributed ceramic particles of the composite, leading to an enhanced higher hardness of 136 VHN and higher tensile value of 373 MPa due to squeezing pressure and B4C particles. The prime intern of the wire electrical discharge machining process was adopted for investigating the machinability of stir cum squeeze cast high-strength A413 with 12 wt% B4C composite. The stratagem of response surface methodology along through central composite rotatable design was taken towards systematic design of experiments. The experimental study results exhibited a possibility of higher amount of metal removal rate for maximum pulse on-time and peak current values, and also better surface roughness was acquired for higher values of pulse off time. The mathematical model shows excellent prediction in accordance with experimental data which seems to fall inside the bounds of acceptable average error around 6.47% and 1.52% for metal removal rate and surface roughness through additivity tests, respectively. The proposed multi-response optimization results revealed a great potential for improving machined surface quality which could be utilized according to the industrial requirements.

Experimental investigation for the effects of wire EDM process parameters over the tapered cross-sectional workpieces of titanium alloys (Ti6Al-4V)

Abstract. The main purpose of this research is to examine the outcomes of process parameters of Wire Electro-discharge Machining over the tapered workpieces of Titanium Alloy (Ti6Al-4V). Taper angle, current and pulse-off time are considered as the controllable factors effecting the response variables. Each sample has been cut with varying sets of machine controllable parameters to assess their effect on response variables; kerf width, wire wear, Material Removal Rate and surface roughness. Analysis of variances is applied, and mean Reponses are determined to recognize and compare the most influencing parameters over the response variables for the WEDM Process. Regression model for the response variables are also developed using which optimized WEDM process parameters are determined for the optimal response variables. It can be concluded that varying thickness of materials due to tapered cross section affects all the four-response variable, while, current and pulse-off time along with their interactions have high impact over the response variables.

Multi-objective optimization of wire electrical discharge machining of 20MnCr5 alloy steel

PurposeWire electric discharge machining (WEDM) is a non-conventional machining process, which is used to provide difficult and intricate shapes. The purpose of this research work is to apply Taguchi’s technique to optimize the process parameters in WEDM. Alloy steel 20MnCr5 has been selected as base material for experimentation. The effects of the input process parameters such as wire type, pulse-on time, pulse-off time, peak current, wire feed rate and servo voltage have been calculated on the material removal rate (MRR) and surface roughness (Ra) in WEDM operation.Design/methodology/approachIn the research work, Taguchi's technique is applied to optimize the process parameters in WEDM.FindingsANOVA indicated that pulse-off time was the most significant factor for the MRR, and servo voltage was the most significant factor for surface roughness (SR). As a part of the project, 20MnCr5 was machined in wire electric discharge machine, and the optimal control parameters were found to get higher MRR and better SR using Taguchi’s technique.Originality/valueTo the best of authors’ knowledge, after reviewing the literature, materials including alloys of metals such as 16MnCr5 and 20MnCr5 have not been investigated so far, and research regarding machining of these materials is limited. Therefore, 20MnCr5 material has been selected for this research work to generate WEDM data.

Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm

Machining of shape memory alloys (SMAs) without losing the shape memory effect could immensely extend their applications. Herein, the wire electric discharge machining process was used to machine NiTi—a shape memory alloy. The experimental methodology was designed using a Box-Behnken design approach of the response surface methodology. The effects of input variables including pulse on time, pulse off time, and current were investigated on the material removal rate, surface roughness, and microhardness. ANOVA tests were performed to check the robustness of the generated empirical models. Optimization of the process parameters was performed using a newly formulated, highly efficient heat transfer search algorithm. Validation tests were conducted and extended for analyzing the retention of the shape memory effect of the machined surface by differential scanning calorimetry. In addition, 2D and 3D Pareto curves were generated that indicated the trade-offs between the selected output variables during the simultaneous output variables using the multi-objective heat transfer search algorithm. The optimization route yielded encouraging results. Single objective optimization yielded a maximum material removal rate of 1.49 mm3/s, maximum microhardness 462.52 HVN, and minimum surface roughness 0.11 µm. The Pareto curves showed conflicting effects during the wire electric discharge machining of the shape memory alloy and presented a set of optimal non-dominant solutions. The shape memory alloy machined using the optimized process parameters even indicated a shape memory effect similar to that of the starting base material.

Selection of WEDM parameters to measure the performance and productivity of die steel grade D3 using GRA and fuzzy logic system

PurposeThe purpose of this paper is to examine the performance parameters of WEDM to improve the productivity and material removal rate (MRR) with a high surface finish of high chromium-high carbon dies steel.Design/methodology/approachThe experiments were performed on AGIE CUT 220 CNC WEDM. High chromium-high carbon dies steel (D3) was used in the form of a rectangular plate. The workpiece and the brass wire having diameter ɸ 0.25 mm had linked up with +ve and –ve polarity in the DC power source, respectively. De-ionized water having a conductivity level of 0.6 µs/cm was used as the dielectric medium. The dielectric fluid was flushed from the top and bottom nozzles and material was submerged in the dielectric.FindingsThe WEDM process parameters for D3 die steel had optimized by using Grey relational analysis method couples with Taguchi method. The optimum solution has been calculated for MRR, cutting speed (Cs), machining time and surface roughness (SR) (Ra value). A fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, cutting speed (Cs), machining time (M/c time) and SR with respect to changes in input parameters.Research limitations/implicationsThe fuzzy model shows the 96.19 percent accuracy between the experimental values and the predicted values.Practical implicationsThe optimized parameters by multi-parametric optimization method showed considerable improvement in the process and will facilitate the WEDM, tool and die industries, defense and aerospace industries to improve the productivity with the higher surface finish.Originality/valueThis manuscript represents valid work and the authors have no conflict of interests. The attained optimum outcomes had also been examined through a real experiment and established to be satisfactory.