Wire Cut Electrical Discharge Machining Process Research Articles

Effect of Al7075 and activated carbon reinforced composite on optimizing WEDM responses

This paper presents wire cut electrical discharge machining (WEDM) response characteristics of Aluminium 7075 (Al7075) reinforced with powdered activated carbon (PAC) composite. In recent days WEDM has become a significant machining process in targeting its benefits of contributing improved material removal rate (MRR) and low surface roughness (SR). This is due the rising need for intricate, accurate, and superior structural components, the WEDM process emerges as a formidable alternative to traditional machine tools. In this work Pulse-on time (Ton), pulse-off time (Toff), discharge current (IA) and servo speed rate (SS) are the variables to be given as input and machining responses such as MRR and SR are studied. From Analysis of Variance (ANOVA) study it is found that discharge current and servo speed is the significant parameters. The optimal desirability condition is obtained with input parameters Ip: 2000 mA; Ton: 8.9 μs; Toff: 25 μs and SS: 150 rpm for the precision machining. The optimum response parameters are found as MRR 10.46 mm3/min and SR 3.32 μm. Results shows that the model designed for the prediction of MRR produces an above 98.27% and the prediction of SR is above 97.17%. The error percentage among the experimental and predicted MRR and SR were estimated. Additionally confirmatory test is performed with optimal results achieved from response surface methodology (RSM) and desirability technique. Metallurgical tests like electron backscatter diffraction analysis (EBSD) and microstructure are conducted to confirm the surface properties and atomic force morphology (AFM) analysis is applied to clarify the structural features of machined composites. The results revealed that the variation of hard deflection is caused by depression of eroded materials on the top layers of machined surface.

Recent Research in Wire Cut Electrical Discharge Machining Process

A product's shape and size are developed through the manufacturing process, which is essential to all sectors. With its unique thermal machining technique, Wire Cut Electrical Discharge Machining (WEDM), items with sharp edges and varied hardness that prove challenging to produce using conventional machining methods can be precisely machined. Utilizing the widely used non-contact material removal technique, the practical technology of the WEDM process is based on the typical EDM sparking phenomenon. When the process was first introduced, WEDM has developed from a crude way to make tools and dies to the best way to produce micro-scale parts with the highest level of surface finish quality and dimensional accuracy. This paper reviews the extensive amount of research done from the EDM process to the development of the WEDM. It reports on the WEDM research that involves optimizing the process parameters and examining the impact of various factors on productivity and machining performance. The impact of multiple WEDM process input parameters, including wire speed, peak current, pulse on and off times, and peak on material removal rate (MRR), surface roughness (Ra), and micro structural analysis, on various process output responses is reviewed in this study.

Design, fabrication, and characterization of a high-sensitivity integrated quartz vibrating beam accelerometer.

This paper describes the design, fabrication, and characterization of a quartz vibrating beam accelerometer consisting of a metal spring-mass and quartz double-ended tuning forks (DETFs). In this approach, the inertial force of the proof mass pulls or compresses the DETFs, affecting their resonance frequency and, thus, enabling the quasi-digital measurement of acceleration. An isolation structure was specifically designed to prevent the external interference stress from transforming into the DETFs and to decrease the DETFs' thermal stress as the ambient temperature changes. A stress-free and high-precision wire-cut electrical discharge machining process was introduced to solve the fabrication problem of flexible hinges, and a femtosecond laser was used to release the proof mass, comprehensively considering the compatibility of the fabrication process and structural design. The oscillation excitation and detection of the DETFs were analyzed, and the DETFs were fabricated using a micro-electromechanical systems process. Sensor dimensions were optimized to improve sensor sensitivity. An accelerometer prototype was fabricated, and its performance was characterized. The tested scale factor was 157.28 Hz/g, and its stability was 16.54 ppm. The bias stability and 1g stability at 1h were 18 and 7.84 µg, respectively. The experimental results validated the feasibility of the sensor design.

PREDICTION OF SURFACE ROUGHNESS IN WIRE CUT ELECTRIC DISCHARGE MACHINING OF AL-FE-SI ALLOY COMPOSITES USING TAGUCHI TECHNIQUE AND REGRESSION ANALYSIS

Wire cut electric discharge machining (WCEDM) is a flexible and more essential for the precise machining of hard materials like composites and super alloys. In order to improve the surface texture as the main focus of the WCEDM process, the expansion of the fundamental procedural perceptive is very important. This paper mainly focuses on the prediction of surface quality of Al-Fe-Si alloy (AA8011) matrix composites during the WCEDM process. For the fabrication of composites, the varying proportions (0, 5, 10 and 15 wt.%) of ZrO2 ceramic particle were incorporated with AA8011 matrix alloy by using stir casting method. In the machining studies, to investigate the effects of reinforcement (wt. %) and the WCEDM process parameters, namely pulse current (amps), pulse-on time ([Formula: see text]s) and pulse-off time ([Formula: see text]s) on machining performance like surface roughness (SR) of the proposed composites. Based on the selection of parameters and their levels, an L16 (44) orthogonal array was most suitable for conducting the WCEDM experiments. A Taguchi technique was employed in this study to determine the optimal conditions of machining parameters through the signal-to-noise (S/N) ratio analysis. The result shows that the minimum SR is achieved at 5 wt.% of reinforcement, 6 amps of pulse current, 110 [Formula: see text]s of pulse-on time and 50 [Formula: see text]s of pulse-off time, respectively. Analysis of variance (ANOVA) results revealed that the reinforcement wt.% has the primary significant factor on SR, trailed by pulse-on time and pulse current, respectively. Furthermore, the regression equation was also developed to predict the SR and that values well agree with the experimental SR.

Comparative study on near-dry wire-cut electrical discharge machining process using moistened wire

Comparative study on near-dry wire-cut electrical discharge machining process using moistened wire

Studies on effect of wire EDM process parameters on machining characteristics of Inconel 825 plate

Wire-cut Electrical Discharge Machining (WEDM) is an emerging engineering process in the field of micro parts manufacturing to fabricate the complex shapes of micro products. This machining method has been magnificently employed in machining various materials starting from Al metal, a highly ductile material to a very high hard material like ceramics and Inconel’s. Inconel and Ti-based alloys treasure trove wider applications in these present industries. Those parts are producing difficulty in several machining processes and create difficult interactions with machining process parameters. Inconel 825 is a Ni-based strength metal and temperature resistant. Conventional machining of these results in large amounts of cutting forces, more strain-hardened and toughened chips, and extreme tool wear. In this work, an effort is made to study the influence of WEDM process parameters such as Ton, Toff and WF on the output variables such as the Cutting Width of Wire-cut EDM for Inconel 825. Preliminary trials were conducted by varying the process parameters in order to design a process parameter window. Factorial design matrix has been developed with L9 numbers of experiments and the corresponding output/responses such as Kerf Width and surface roughness (Ra) were measured and recorded. The responses have been used to measure the Ra and kerf values of all the specimens after cutting by Wire cut EDM machine. Use of ANOVA using identifies the influenced process parameter on machining (cutting) Inconel 825 output responses Kerf Width and surface roughness.

Enhancing Wire-EDM Performance with Zinc-Coated Brass Wire Electrode and Ultrasonic Vibration

This study aimed to investigate the performance of zinc-coated brass wire in wire-cut electrical discharge machining (EDM) using an ultrasonic-assisted wire on tungsten carbide. The research focused on the effect of the wire electrode material on the material removal rate, surface roughness, and discharge waveform. Experimental results demonstrated that using ultrasonic vibration improved the material removal rate and reduced surface roughness compared to conventional wire-EDM. Cross-sectional SEM of the white layer and discharge waveform were investigated to explain the phenomena of ultrasonic vibration in the wire-cut EDM process.

WEDM process parameters optimization by preference-based CS & PSO algorithm for LCP

ABSTRACT Locking Compression Plates (LCP) are typically made of Ti6Al4V alloy. LCP is used to heal fractures of the bone. This article uses Wire Cut Electric Discharge Machining (WEDM) to machine Ti6Al4V alloy. Responses are optimized by two metaheuristic algorithms, the cuckoo search algorithm (CS) and particle swarm optimization (PSO). The cuckoo search algorithm shows that the maximum MRR is 59.4312 mg/min & the maximum cutting speed is 5.0625 mm/min. The single-objective PSO shows a maximum MRR of 59.3632 mg/min & the maximum cutting speed is 5.0155 mm/min. The GRA revealed that the optimum weight for MRR and cutting speed is 48.868% and 51.132% respectively. Scanning electron microscope analysis indicates proper biocompatibility after machining. This article compares CS and PSO with similar calculations for the t-test and found that the p-values for MRR and Cutting speed are 0.9432 and 0.9919.

Optimization on Material Removal Rate and Surface Roughness of Stainless Steel 304 Wire Cut EDM by Response Surface Methodology

In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop products in a very short development cycle and at a better economic rate. In this paper, the selected complex geometry of the metal sample was eroded away from the wire during the WEDM process, which eliminates mechanical tensions during machining. The effect of different WEDM operation variables set as wire speed, wire tension, discharge current, dielectric flow rate, and pulse on and off time on the parameter, stainless steel 304 material removing rate (MRR) using RSM, has been studied. The MRR will be maximized if the optimum sets of operational variations are used and also achieve a superior surface finish.

Performance Improvement of Wire-Cut Electrical Discharge Machining Process Using Cryogenically Treated Super-Conductive State of Monel-K500 Alloy

Performance Improvement of Wire-Cut Electrical Discharge Machining Process Using Cryogenically Treated Super-Conductive State of Monel-K500 Alloy

Al-Mg-MoS2 Reinforced Metal Matrix Composites: Machinability Characteristics.

Several components are made from Al-Mg-based composites. MoS2 is used to increase the composite’s machinability. Different weight percent (3, 4, and 5) of MoS2 are added as reinforcement to explore the machinability properties of Al-Mg-reinforced composites. The wire cut electrical discharge machining (WEDM) process is used to study the machinability characteristics of the fabricated Al-Mg-MoS2 composite. The machined surface’s roughness and overcut under different process conditions are discussed. The evaluation-based distance from average solution (EDAS) method is used to identify the optimal setting to get the desired surface roughness and overcut. The following WEDM process parameters are taken to determine the impact of peak current, pulse on time, and gap voltage on surface roughness, and overcut. The WEDM tests were carried out on three different reinforced samples to determine the impact of reinforcement on surface roughness and overcut. The surface roughness and overcut increase as the reinforcement level increases, but the optimal parameters for all three composites are the same. According to EDAS analysis, I3, Ton2, and V1 are the best conditions. Furthermore, peak current and pulse on-time significantly influence surface roughness and overcut.

Influences of cryogenically treated work material on near-dry wire-cut electrical discharge machining process

In this research, influences of cryogenically treated Inconel 718 work material in near-dry wire-cut electrical discharge machining (WEDM) characteristics have been studied using argon-mist (mixing of pressurized argon gas and minimum amount of tap-water) and a reusable Molybdenum wire tool. The effect of cutting parameters (pulse width (PW), spark current(C), pulse interval (PI), and flow rate(F)) on surface roughness (SR) and cutting rate (CR) and using Box-Behnken response surface analysis. It was observed that CR and SR are increased by increasing PW, and C; conversely, reduced by increasing PI. The technique for order of preference by similarity to ideal solution (TOPSIS) method has been utilized to estimate the best parameters’ settings for improving both machining characteristics. The optimum CR (9.81 mm3 min)−1 and SR (1.9 μm) have been obtained by optimum settings of 4 Ampere spark current, PW of 20 μs, PI of 72 μs, and 18 ml min−1 of the flow rate of mixing water using the TOPSIS method. The best settings of cutting parameters obtained from the TOPSIS method were considered to compare the near-dry WEDM performance using cryogenically treated/untreated work materials. It was observed that CR and SR of the cryogenically treated work material are 9.17% increased and 21.58% reduced than the untreated work material due to an increase in electrical and thermal conductivities.

Estimation of machinability performance in wire-EDM on titanium alloy using neural networks

ABSTRACT The impact of process factors on wire-cut electrical discharge machining (WEDM) performance is complex and nonlinear. In the present work, initially, the WEDM tests were conducted on titanium alloy (Ti-6Al-4V) with eight input factors and four machinability performance parameters. Later, an artificial neural network (ANN) model was established to estimate the WEDM performance. The ANN model with 8-5-5-4 architecture produced a least mean squared error (MSE) and average prediction error (AE) for both training and test data sets. The precision of the ANN model was assessed by relating model predictions with the experimental values. The combined effect of WEDM variables on the machinability performance was illustrated with the help of visual graphs. The R-value (correlation coefficient) of 0.9995 among WEDM test values and ANN estimated values shows the robustness of the developed ANN model in establishing the link between WEDM process factors and machinability parameters. The proposed model helps in minimizing the time for fixing the process parameter values, thereby increasing production and process efficiency.

Parametric study using response surface methodology of Ti-Al2O3 (15 vol% of Ti taken as Al2O3 reinforced as alumina fibre into titanium matrix) composite material while undergoing WEDM process

For the last few decades a tremendous demand has been observed in terms of developing new engineering materials to cater the need of the modern century especially in the aerospace and automobile industries. Thus new composites materials are evolved especially metal matrix composite materials to fetch the growing desire of the world. But the problem lies machining these composite materials with conventional machining processes become very difficult and thus new machining technologies becomes inevitable to fulfil this demand. New machining processes also emerged to provide a better and alternative machining to these newly fabricated composite materials. In this context when the world demands for new engineering materials to fulfil the market requirements and machining these modern materials by non-conventional machining processes, the present research work aims to put a light on this particular research field. In the present research work attempt has been taken to fabricate Ti-Al2O3 composite material where 15 vol% of Titanium taken as Alumina reinforced as Alumina fibre into Titanium Matrix to form this Titanium Matrix Composite (TMC) material. Wire Cut Electric Discharge Machining (WEDM) has been used in the present research work as a non-conventional machining process to machine this type of TMC material. Response Surface Methodology of BBD technique has been used to analyse the different parametric effects of WEDM over the output responses. The theoretical results and the experimental data are compared in the present research work and are found to be satisfactory. Confirmatory test suggests that the percentage errors are very less which justify the present research work. Optimal WEDM input parameters are also calculated in the present research work which provides the best output responses for Ti-Al2O3 composite material while machining with WEDM process in this present work.

Experimental Study of Process Parameter for Surface Roughness in WEDM

Wire cut Electrical-Discharge Machining (WEDM) is a machining process which utilizes a thin wire (around 0.18mm) for material removal. In modern machining of complex object, it plays an important role. Process parameters have great in-fluence on WEDM. MRR, SR and WT are varying process parameters. In this article surface roughness (SR) in WEDM process was analysed using Taguchi method. To validate the results analytical and experimental results were investigated. In experiments it was observed, when peak current value was increased, SR value also increases and in resultant a rough surface was produced. Peak current was observed as most influential parameter with contribution of 82.12%.

Optimization of electrical process parameters of WEDM on ECAP Al7075 alloys considering Radial Overcut (ROC) as output response

The aim and objective of the present experimental work is to find out the predicted value of Radial overcut (ROC) while processing of Al7075 alloy through Equal Channel Angular Pressing (ECAP) with channel angel 90 degree and edge angle 20 degree with chosen process route C and alongwith suitable back pressure and subsequently machining that ECAP sample by Wire cut electric discharge machining (WEDM). Response Surface Methodology is applied in present study to predict the ROC in WEDM process for previously ECAP Al7075 alloy. Pulse off time (Toff), pulse on time (Ton), peak current (IP) and servo voltage (SV) are taken as input electrical parameters of process to study the ROC. The experiment was designed to perform based on Central Composite Design (CCD) method. After performing 31 experimental runs a mathematical model was being evolved for finding out the correlation and significance of electrical parameters on ROC. The coefficients were obtained by performing analysis through ANOVA at 95% confidence level.Observation shows that Ton and IP has got significant impact on ROC. The forecasted results based on mathematical model generated are found to be in a reasonably good degree of accuracy with the experimental result. Optimum value of radial overcut is obtained experimentally as 26.075 µm against Ton 7 µs, Toff 54 µs, for IP value 100 A and SV 25 V respectively.

An investigation on gas emission concentration and relative emission rate of the near-dry wire-cut electrical discharge machining process.

Wire-cut electrical discharge machining (WEDM) is the highly essential unconventional electrothermal machining process to cut the contour profile in the hard materials in modern production industries. The various environmental impacting contaminants (by evaporating and reacting liquid dielectric fluid) have been produced during the conventional WEDM process and are harmful to the machine operators. These wastes have been minimized by the near-dry WEDM process in which the pressurized air mixed with a small amount of water is used as a dielectric medium. In this research, influences of machining parameters (air pressure, flow rate mixing water, spark current, and pulse width) on gas emission concentration (GEC), material removal rate (MRR), and relative emission rate (RER) of near-dry WEDM process have been optimized by the Taguchi analysis. RER has been determined to analyze the variations of gas emission concentration per unit quantity of material removal by changing the process parameters. It was revealed that the maximum air pressure and flow rate of mixing water have been predicted as significant parameters on GEC and RER. While comparing wet and near-dry WEDM processes, the material removal rate of near-dry process is comparable to that of wet WEDM with minimum GEC and RER.

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

A study on cryogenically treated molybdenum wire electrode

The molybdenum wire has been used as a cutting tool in the wire-cut electrical discharge machining process. In the cryo-cooled near-dry machining process, the cryo-cooled wire has been used as a cutting tool. In this paper, the hardness, electric conductivity, wear resistance, and surface microstructure of cryogenic treatment (immersed into liquid nitrogen) of molybdenum wire has been analyzed concerning the different cooling period. As per the literature survey, some investigations are required on the physical properties of Cyro-cooled molybdenum wire with lower temperature. The wire electrode was cryogenically treated by liquid nitrogen with one, two, and three hours of period. The specimens were initially prepared and dipped into liquid nitrogen in a Dewar's vessel for various time intervals and observe the physical properties modification. The hardness, electric conductivity, wear resistance, and microstructure of the cryogenically treated wires with untreated wire have been compared. It was observed that when the cooling period is increasing, then, the hardness, electric conductivity, wear resistance, and surface microstructure of wire have been improved.