Wire-cut Machining Research Articles

Effect of Temperature on Magnetic Characteristics of NdFeB Alloy

NdFeB magnets were first developed in 1984 and are the most powerful permanent magnets that may possess energy products up to 60 MGOe. However, their working temperature and corrosion resistance are lower as compared to that of Alnico and SmCo magnets. Demand of NdFeB magnets recently has increased due to rapid growth of electrical vehicles. In this research work, NdFeB magnets developed through powder metallurgical technique are investigated for thermal effect on magnetic characteristics. The effect of increase in temperature on remanence, coercivity and energy product were measured using pulsed field magnetizer. Samples for testing were prepared from sintered bricks using wire cut machine. Demagnetization curves for the samples were measured at temperatures in the range of 20-110°C, and the results were analyzed. Decline in magnetic characteristics with temperatures is noted. Performance of the magnets with increase in temperature is essential to be analyzed specially for their use in high-speed motors.

Design of electrical cabinet wire cutting machine based on STM32

Abstract The wire in the electric cabinet is one of the keys to ensuring the normal operation of the electric cabinet. In order to improve the production efficiency of wire cutting, this project designed a wire-cutting machine for an electrical cabinet, which could recognize the CSV table file of the electrical cabinet wiring list on a U disk and cut wires of different lengths and quantities according to the order in the file. The main control chip of the device uses STM32 single chip microcomputer (STM32F103C8T6) and CH376S module to realize the function of reading CSV file on U disk through serial communication. In terms of control, the device adopts a proportional-integral-differential (PID) control algorithm to achieve accurate control of the JGB37-520 gear motor and TD-8120MG steering gear and then realizes wire feeding, wire stripping, cutting, and other functions. The experimental results show that the average relative error of length is about 0.5%, and the error is within a reasonable range.

IMPLEMENTATION OF RELIABILITY CENTERED MAINTENANCE (RCM) II IN PACKAGING INDUSTRY PRODUCTION MACHINERY MAINTENANCE ACTIVITIES

Along with the increasing need for productivity and the use of high technology in the form of production machines and factories, the need for maintenance functions is also increasing. At PT. Weiss Tech, a packaging machine manufacturer, has problems mainly related to wire cut machine malfunctions which cause interruptions and delays in the production process and reduce machine performance. In overcoming these problems in this study, the Reliability Centered Maintenance (RCM) II method from Failure Modes and Effect Analyze (FMEA) was used. RCM II is one of the methods used to determine which components are due for repairs, while FMEA is defined as a method for identifying the root cause of engine failure. From the results of calculations using FMEA and RCM II, the results of the maintenance interval for the Electromotor component (electric motor) with a maintenance interval of 20 hours, for the Lower and upper nozzle components (upper and lower nozzles) with a maintenance interval of 181 hours, and for the Roller component (drive roller) ) with a treatment interval of 177 hours

Experimental Investigation of the Effects of Machining Parameters on the Performance of Form-Cutting Tools Manufactured by Wire Electrical Discharge Machining (WEDM) and Grinding Processes.

In this research, a comparison between two methods of grinding and WEDM and the chip formation of each form tool was studied through a set of designs of experiments. A multi-functional form tool with different cutting-edge shapes was designed to compare different production methods, and a grinding machine and a five-axis wire-cutting machine were made. The form tools by the wire cutting method were made with three different machining states, rough, semi-finish, and finish. The results of the experimental test showed that the chip formation of the finished surface of the wire cut tool was close to the ground tools. Additionally, the tool life in wear generation was assessed, revealing that the tool generated through the wire-cutting method with three passes exhibited superior performance compared to alternative approaches. Furthermore, employing the wire-cutting technique with high surface finishing yielded optimal outcomes for producing form-cutting tools featuring complex profiles.

Slippery surface with ternary coupled structures for improving lubricant-storage capacity

A slippery surface has the capability to protect the substrate surface, which can prevent substrate corrosion in a harsh environment. However, existing slippery surfaces have the limitation of insufficient oil-locking capability for rough structures, which limits their practical application. To solve the aforementioned limitation, the authors developed a slippery surface with a good oil-locking capability. First, a wire-cutting machine tool was used to fabricate ternary coupled grooved structures on an aluminum (Al) substrate, which could increase the lubricant-storage capacity of the microstructures, and the substrate was named slippery porous surface with groove-textured aluminum (Slips-G-Al). Then, a surface durability test was performed involving lubricant shear, sandpaper wear and water impact. The chemical stability test involved acid, alkali, salt corrosion and weather resistance tests, which showed that Slips-G-Al had a good lubricant-storage capacity compared with the traditional Slips surface. In addition, the self-cleaning performance and the fog collection capability of Slips-G-Al were also studied. Finally, an electrochemical corrosion test of Slips-G-Al was carried out. The findings showed remarkable application prospects in the aerospace and shipbuilding fields.

Osseointegration and Histological Picture of Titanium Silicon Gallium Alloy vs. Titanium Silicon Alloy and Pure Titanium

Background: Using titanium alloy with gallium and silicon could speed up the process of osseointegration, which would mean that titanium-silicon-gallium alloy could be used in more therapeutic situations. Objective: To evaluate the osseointegration and histological features of a newly fabricated Ti-Si-Ga alloy implant. Methods: Samples were fabricated utilizing the powder metallurgy technique. The titanium matrix was augmented with alloying components. The composite materials were produced by the compaction process at a pressure of 900 MPa, followed by sintering at a temperature of 800°C. For the in vivo test, ninety cylindrical specimens (3x6 mm in diameter and height, respectively) were prepared by using a wire-cut machine to cut the mentioned measurements from a sintered cylinder (15 mm in diameter and 6 mm in height) (6 cylinders for each group). Results: The Ti-Si-Ga group showed the highest bone formation area and higher push-out values than the commercially pure Ti and Ti-Si groups in this study. Conclusion: The use of gallium as an alloying element improved osseointegration.

Effect of support structure design toward residual stress of part build using selective laser melting

AbstractSelective laser melting process required post‐processing of support structure and it is compulsory to use it at overhanging part. There is certain condition where support structure cannot be remove using wire cut machine because of limited access to part and need to be remove manually. This is where the removability of support structure plays important role because support structure needed to be design so that it can be easily remove using manual way. In addition, when comparing contour type of support structure with the most commonly use block type of support structure it shows that contour type is easier to be remove. Furthermore, no research has been done on optimizing the contour type of support structure. A research experiment is conducted in this work to optimize the parameter of contour support structure which is contour offset, teeth height, teeth top length and teeth base length. The result indicates amount of residual stress and the time required for support removal are significantly influenced by contour offset, while all parameters are significant for support volume. The optimum parameter to get low residual stress is contour offset is 0.6 mm, teeth height is 1.4 mm, teeth top length is 0.75 mm and teeth base length is 1.55 mm.

Comprehensive Improvement and Application of Copper Row Chain System of TOBSPIN Tobacco Cutter

In order to solve the problem of abnormal wear of the lower copper row chain of TOBSPIN tobacco cutter, the working principle of the compaction unit of the wire-cutting machine was analyzed. Comprehensive improvements were made to the lower copper row chain system, which effectively reduced the wear on both sides of the copper row chain and prolonged the usage time of the copper row chain. Tested with TOBSPIN shredder used by Ningbo Cigarette Factory, the results showed that the wear speed of the improved copper exhaust chain was reduced from 2.62 mm / 800 h to 0.85 mm / 800 h, down by 67.6%. This method can support improving the service life of TOBSPIN tobacco cutters.

A novel design method of circular sandwich panels with gradient continuous controllable core based on space-filling design and 2D-Voronoi method

In this paper, a novel method based on the space-filling design and 2D Voronoi method was proposed to design the in-plane gradient continuous controllable honeycomb (GCCH) structures. Low-velocity impact tests were carried out using the sandwich panels with GCCH core layers, which were all made of Aluminium alloy material and fabricated with the wire-cut machine. A concise theoretical solution for loading capacity and denting profile was developed and verified. Three-dimensional finite element models were implemented in ABAQUS/Explicit to model sandwich panels.The FE models were validated with experimental results and, subsequently, the simulation results were further extended to study the impact response and energy absorption characteristics. Results show that the method proposed in this work was effective to design multi-cell structures with graded mechanical properties in the radius direction and approximately homogeneous in the circumferential direction by controlling the distribution of the sites. Sandwich panels with GCCH core layers had better energy absorption properties compared with sandwich panels whose core layers were hexagonal honeycomb with similar cell wall lengths.

Augmentation of water pool boiling heat transfer using heating surfaces fabricated by multi passive techniques

Presenting the findings of an experimental examination of heat transmission during pool boiling on microstructure copper heating surfaces modified in various ways, this paper. The microstructured surfaces are fabricated using the wire-cutting machine, laser-processed surface technique, and sandpaper. Using pure water as the pool boiling liquid, microstructured surfaces' heat transfer coefficients (HTC) are estimated experimentally. The tests are conducted at atmospheric pressure in a saturated pool boiling state with a heat flux ranging from 50 to 580 kW/m2. The results showed that a maximum improvement of 51–92 % was obtained using composite surface modification technology by forming a microscopic structure on the surface of the heat source.

MBFA algorithm based optimization of tungsten carbide alloy wire cut machining process

MBFA algorithm based optimization of tungsten carbide alloy wire cut machining process

Optimization of Wire Cut Electro Discharge Machining Process Parameters for Aluminium 6082 by using Taguchi Technique

Abstract: The manufacturing industry is changing very drastically in all the aspect regarding the manufacturing technology as well as the quality concern as per as the quality is considered. Quality is becoming a significant trend in todays growing automobile industry. In the field of metal cutting operations, the surface roughness is becoming more dominant parameter as per as the quality of the component is considered. Electrical discharge machining is becoming a most powerful non conventional machining which is being widely used in the field of machining. Most specifically our work was conducted on the electrical discharge wire cut machining for achieving the desired surface roughness (Ra) and adequate material removal rate (MRR). The input parameter for our research work were selected as Peak current, pulse on time & pulse off time while the output parameter was selected as MRR and the surface roughness. Aluminum 6082 Grade material is used as a specimen and the research methodology implemented for the research work is taguchi and Anova. Keywords: Wire cut EDM, Taguchi, MRR surface roughness, Anova.

Performance evaluation of SiC powder mixed electrical discharge machining: a case of wire cut mode with re-circulating molybdenum wire

A review of the available literature on powder mixed electrical discharge machining (PMEDM) indicates that most of the research has been done for “die sinking machining mode” whereas the “wire cut machining mode” has not received due attention despite being an important process variant. This work employs silicon carbide (SiC) powder mixed dielectric fluid for machining of AISI D2 in “wire cut” mode with re-circulating molybdenum wire (an economic and chemically stable proposition as a tool). The effect of five process parameters (powder concentration, peak current, pulse on time, nozzle flushing pressure and stand-off distance) has been evaluated on surface roughness, kerf width, material removal rate, and wire wear ratio using Taguchi’s approach followed by analysis of variance (ANOVA) for determining statistically significant factors at 95% confidence level. It is found that for surface roughness, higher current and low to moderate concentration levels (2 to 4g/l) deteriorate surface quality; higher values of pressure and stand-off distance are also seen to adversely affect it. For material removal rate, pulse on time as well as its interactions with powder concentration and current, are statistically significant. A higher pulse on with smaller and moderate powder concentrations (2g/l and 4g/l) reduces MRR. For the wire wear ratio, the current is the sole significant factor (PCR of ~65%). SEM analysis of the machined workpiece for the maximum MRR condition quantifies the recast layer as ~19microns. An indirect comparison with the reported values for non-powdered EDM process indicates that for the similar wire (molybdenum), the use of SiC powder maintains the surface roughness and kerf values, for a much harder D2 material used in this work.

Analisis Kuat Arus dan Wire Speed Pada Permesinan Wire Cut EMS 45 Terhadap Kekasaran Permukaan Roda Gigi Lurus

Wire cut is a high-tech machining process and can be used to make high-precision products. This study aims to analyze the results of the workpiece surface and study the effect of current strength and wire speed on wire cut machining of EMS 45 on the surface roughness of straight gears. The results analyzed were the surface roughness values obtained by testing the surface roughness. The variations in the current used were 3 amperes, 5 amperes, and 7 amperes, while the wire speed used was 8 mm / min, 10 mm / min, and 12 mm / min. In the wire cut machining process, brass cutting materials are used with a wire diameter of 0.25 mm. The results showed that the greater the current and wire speed used, the lower the surface roughness value, conversely the smaller the current and the wire speed used, the higher the surface roughness value. The results of data analysis using the ANOVA analysis method, correlation, and regression get the optimal conditions for obtaining low surface roughness values and fast cutting time, namely at a current of 7 amperes with a wire speed of 10 mm/min.

Natural Convection between A Pair of Elliptical Cylinders in Blunt and Slender Situations (Dept.M)

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Development and mechanical characterisation of Al-4.5%Cu alloy prepared using spark plasma sintered method

ABSTRACT Spark plasma sintering of Al-Cu composites yields a refined low segregation microstructure and the conversion of spherical grains to irregular non-dendritic structures during the cooling phase of the process. Al-4.5Cu alloy powder with an average particle size of 210 to 250 µm was gas atomised in an inert gas for physical and mechanical characterisations. The alloy powder was compacted into cylindrical specimens of 30 mm diameter and 20 mm thickness. The Al-4.5 wt. % Cu alloy powder was filled in enclosed graphite die and with the application of pressure and heat, the sintering samples were developed. For microstructural characterisation and mechanical properties, test samples were prepared by using Electrical discharge machining wire-cutting machine according to ASTM standards. The density of the alloy was improved in the range of 4.7% to 7.8% and the hardness value was improved by more than 100% when compared to the conventionally sintered Al-4.5Cu alloy. The compressive strength of the spark plasma sintered alloy is much higher than the conventionally sintered alloy samples by 307.32%, 150.15% and 47.45%.

Effect of Wire Diameter, Feeding Rate, Pulse (on/off) Time on Surface Roughness and Metal Removal Rate for Cr-Mo Steel (SCM425H) During Wire Electrical Discharge Machine (WEDM) Cutting Operation

Increase the demand to produce complex shapes with high quality and dimensional accuracy such as production aerospace, cars, die sinking has been leading to increase the demand to use the non- traditional cutting operations such as wire electro-discharge machine (WEDM) rather than using the traditional operations. An idea to understand the effect of wire diameter, wire feed, pulsing (on/off) time on surface roughness, and metal removal rate of Cr-Mo steel during wire electrical discharge machining was investigated. Two Steel alloy samples with dimensions of (60 x50 x 20)mm were cut into four rectangular spaces with (5x10x20)mm at one side of each sample using wire cut (EDM) machine with a wire diameter of 0.25 mm and feeding rate 2 m/min for sample 1 and a 0.3 mm diameter and 3 m/min feeding rate for sample 2. Pulse (on, off) time was (110, 50), (112, 52), (115, 55), (116, 57) corresponds to space 1, space 2, space 3, and space 4 in both steel block. Surface roughness and metal removal rate measurements were estimated. The results showed that wire diameter, feeding rate, and pulse (on, off) time is proportional with metal removal rate, while reversed with surface roughness. The wire diameter of 0.3 mm and a feeding rate of 3m/min enhanced better surface quality and productivity. Pulse (on, off) time is the most effective parameter. Best duration time was recorded at the values (116, 57).

Effect of Ultrasonic Cavitation and Chemical Erosion on TC4 Titanium Alloy in Aluminum Melt

Abstract An ultrasonic radiation rod made of Ti-6Al-4V (TC4) titanium alloy can be eroded in an aluminum alloy casting, which can also affect the stable transmission of ultrasonic waves. This erosion is a result of complex, multifactor interaction. Therefore, two groups of experiments were designed: one group did not apply ultrasonic treatment (UST), while the other group did. Five titanium alloy samples removed from the radiation rod were ground on the automatic grinding machine to make their surface roughness similar. The four samples were placed in the molten aluminum for 4.5, 9, 13.5, and 18 h, respectively, without UST. The remaining sample was placed in molten aluminum with UST for 4.5 h. The four samples without UST were cooled and cut through the middle position by a wire-cutting machine. The cross sections of the four samples were ground and observed by a scanning electron microscope (SEM). The generated chemical layer was determined to be titanium trialuminide alloy (TiAl3) by energy dispersion spectrum (EDS) analysis, and its thickness was approximately 20–50, 145, 220, and 345 μm, respectively, corresponding to different processing times. The fifth titanium alloy sample was processed by UST, the residual aluminum on the sample surface was removed by hydrochloric acid, and obvious erosion pits and microcracks were found by SEM. The roughness of the surface was approximately 340 μm in the LY-WN-YH 3-D system. Therefore, the effect of ultrasonic cavitation on TC4 titanium alloy is much larger than that of a chemical reaction.

Determination of White Layer Characterstics on Machining Process

Now a day’s industries requirement as light weight and high wear resistance component. The component used as a various industrial application areas. The material also high self lubricant material also need. In this work we was used aluminium matrix composite with added in a CNT as a Nano materials. The materials has used to a high wear resistance and it is act as a self lubricant material also the material carry out different percentage and casting used in a stir casting method. The casting sample cut by a testing sample by used in an EDM wire cut machine. The sample carried out the result and plots the graphs. And the samples are carry out wear test using pin on disc method. The result shown in graph. And the sample machining study also did by EDM Wire cut machine. Finally carry out the white layer of the material. The study discussed with the paper. In this research work used in a light weight and self lubricant material needed area

The Effect of Heat Treatment Conditions on the Mechanical Behavior of Ni-Ti Shape Memory Alloys

Ni-Ti shape memory alloy (SMA), and its alloys have been widely used for medical, mechanical and electrical applications. In this study, a (Nitinol) Ni-Ti alloy medical plate was prepared and cut using a wire cut machine. Eight samples were heat treated at 800°C and used for heating samples for 30 min and 60 min at this temperature, then cooled in four media: furnace, water, air, and ice bath. Micro-hardness and microstructure measurements were taken, as characterization techniques, to investigate the effect of cooling rate on mechanical properties. Micro-hardness results showed the HV is 316.36 HV at ice cooling rate for 800 °C and 60 min heating time, and 275.5 HV for 800 °C heating for 30 min and ice cooling media. The results show the correlation between cooling rate and properties of the alloy.