Wire Cut Research Articles

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

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

Gorilla Troops Optimizer Combined with ANFIS for Wire Cut EDM of Aluminum Alloy

Wire cut EDM is a quite regularly used machining process in mechanical and electronic industries. This research has attempted to machine aluminum alloy for which experimental design was prepared using Box-Behnken design. Different combinational options of pulse-on time (P1), pulse-off time (P2), servo wire feed (WF), and current (I) were investigated and surface roughness after machining was observed. Collected 27 datasets were further used in Adaptive Neuro Fuzzy Inference System (ANFIS) to produce about 500 datasets. These 500 datasets are approximated data derived from experimental datasets, known as synthetic data. Data model was further developed and used in Gorilla Troops Optimizer (GTO) to locate the optimum machining parameters. With the excellent three search operators: move towards other gorillas, migrate towards unknown places, and migrate towards known places, GTO has produced the lowest surface roughness value of 0.500953 μm when the machining parameters of pulse-on time, pulse-off time, wire feed, and current values were set as 121 μs, 52 μs, 3 m/min, and 166A, respectively. To ensure the accuracy of the synthetic data-based model and optimality, verification and validation were conducted. Wilcoxon signed rank test was conducted for the pairwise comparison of GTO with each of its competing algorithms at the significance level of σ = 0.05. Friedman test was conducted to calculate the average ranking of each algorithm and to detect the global differences between all compared algorithms. Outperforming performance by GTO algorithm in machining of the selected material is found.

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.

SURFACE MORPHOLOGY AND MACHINABILITY ASPECTS IN WIRE-EDM OF INCOLOY-800 SUPERALLOY: AN EXPERIMENTAL EVALUATION AND MICROSTRUCTURE ANALYSIS

This study investigated various performance measures — material removal rate (MRR), surface roughness (SR), and dimensional deviation (DD) — in wire cut electrical discharge machining of the Incoloy-800 superalloy under the effect of purposefully varied process inputs. Superalloys comprise a bright category of alloys that possess excellent mechanical strength at elevated temperatures, superior surface stability, magnificent creep resistance, and corrosion and oxidation resistance. Analysis of variance was performed to reveal influential and crucial inputs for machining measures; results were interpreted and modeled statistically. After conducting the experimental runs, the novel attempt has further been made to conduct the multi-response optimization with the desirability method and the teaching-learning-based optimization (TLBO) algorithm to develop the best process setting for optimizing all considered measures jointly. Furthermore, machined sample’s microstructure analysis was conducted with the scanning electron microscopy (SEM) analysis. The optimized parametric setting was obtained as follows: pulse on time: 2 [Formula: see text]s, pulse off time: 4 [Formula: see text]s, peak current: 2 A, and wire feed rate: 5 m/min. Obtained experimental values for MRR, SR, and DD were 0.936 mm/min, 3.797 [Formula: see text]m, and 0.084 mm, respectively, with the combined desirability value of 0.601. Optimization values of MRR, SR, and DD through the TLBO method varied from predicted values by 3.01%, 6.86%, and 6.32%, respectively.

Studying the Effect of Ignition Voltage (Ue) and Amperage (Ie) when Processing Hardened SKD 11 Materials on Wire Cut Electric Discharge Machining (WEDM)

Studying the Effect of Ignition Voltage (Ue) and Amperage (Ie) when Processing Hardened SKD 11 Materials on Wire Cut Electric Discharge Machining (WEDM)

Design of a Noncircular Gear Mechanism With Twice Unequal Amplitude Transmission Ratio

Abstract This article proposes a new noncircular gear transmission mechanism with an involute–cycloid composite tooth profile to obtain the twice unequal amplitude transmission of noncircular gears. That is, the instantaneous transmission ratio has twice obvious fluctuations with unequal amplitude in a complete rotation cycle of gear transmission. The twice unequal amplitude transmission ratio curve was designed based on Fourier and polynomial functions, the change law of the Fourier coefficient on the instantaneous transmission ratio was analyzed, and the pressure angle and contact ratio of the involute–cycloid composite tooth profile was calculated. The involute–cycloid composite tooth profile noncircular gear was machined by wire cut electrical discharge machining technology, while its meshing experiment was performed using high-speed camera technology. The results demonstrate that the instantaneous transmission ratio curve value obtained via the high-speed camera experiment was consistent with the simulation value of virtual software. Furthermore, the involute–cycloid composite tooth profile was applied in the seedling pickup mechanism of noncircular gear planetary gear train. The possibility of the application of the involute–cycloid composite tooth profile in the seedling pickup mechanism was verified by comparing the consistency of the theoretical and simulated seedling picking trajectory.

Online modeling and monitoring of power consumption, aerosol emissions, and surface roughness in wire cut electric discharge machining of Ti-6Al-4 V

Online modeling and monitoring of power consumption, aerosol emissions, and surface roughness in wire cut electric discharge machining of Ti-6Al-4 V

Performance of different wire electrode materials on kerf width in WEDM of aluminum hybrid composite

This research is about investigating the influence of wire materials like uncoated brass wire, diffused and zinc coated brass wires in kerf width in the wire cut EDM (wire cut electrical discharge machining) of novel Aluminum hybrid metal matrix composite material. The stir casting is used to synthesise Aluminum hybrid metal matrix composite materials in such a way that Aluminium alloy 6061 reinforced with 5% Silicon carbide (SiC) and 5% graphite. The response surface methodology based design of experiments utilized to optimize the independent parameters like gap voltage, pulse times like Pulse off and Pulse on as well as discharge current for minimizing the dependent variable of kerf width. It was found that the machinability performance of novel Aluminum hybrid metal matrix composite material in WEDM is comfortable with brass wire which was zinc coated in terms of minimum kerf width.

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.

Experimental investigation of WEDM control parameters for AZ61 Mg alloy using ANN modeling

Wire cut electric discharge machine (WEDM) is a spark erosion process used to make intricate shape of conductive material by moving wire. Now a day every person wants a good quality at low cost. For this purpose, AZ61 alloy is used as a workpiece and analysis is carried out to find out the significant process parameters. In the current work, the influence of different parameters of WEDM like pulse on time, pulse off time, servo gap voltage, peak current, wire feed rate, water pressure, wire tension and servo feed on response i.e., cutting speed (CS) have been investigated while machining AZ61 alloy material. The CS values are predicted using Artificial Neural Networking (ANN) modeling and compared the experimental values. From the results, the predicted values are observed nearby the experimental values.

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.

Machinability study of Incoloy using different wire electrode in Wire-Cut EDM

Increase in the usage of nickel-based superalloys in the field of aviation, marine industry, nuclear reactor due to its excellent mechanical properties like corrosive resistance, carburization resistance especially at elevated temperature. Nickel based superalloys are very tedious to machine in conventional because of high strength, less conductivity of thermal, strain hardening property. In this study, one of the best Unconventional machining processes i.e., Wire electric discharge machining is used for machining of Inconel 800 (Incoloy). Zinc coated brass wire; Cryogenic cooled zinc coated brass wire electrodes are used in Wire cut EDM. RSM technique is used to plan experiments with Wire tension, Pulse on time and Wire feed as varying parameters, keeping Servo voltage and Wire feed as constant. Material removal and Roughness of surface are compared for Zinc treated brass and Cryogenic cooled (LN2) Zinc treated brass and optimizing responses i.e., by using lower the better and higher the better criteria.

Examination of microstructure properties of AISI 316L stainless steel fabricated by wire arc additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is a fusion manufacturing or Wire-feed additive manufacturing for creating components by layer-by-layer technique. WAAM has been a viable replacement to traditional machining because of its ecological protection, high deposition rate, minimizes the wastage, and competitive pricing. WAAM technique is used to manufacture multipart designed products.316 L stainless steel plate was fabricated in this investigation using ER 316 L consumable wires and a welding robot system. Current, Voltage, welding speed, gas flow rate, and shielding gas were used as experimental factors. Micro wire cut electric discharge machining was used to remove the base plate and side edges, and the processed plate surface was polished with help of vertical milling machine. To check the microstructure behaviors like Scanning electron microscope, Macro test and Surface roughness test was performed. The process of additive manufacture of 316L stainless steel is found to be practical using this experimental work.

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.

Performance Evaluation of WEDM using Parametric Variation

Wire cut Electrical-Discharge Machining (Wire-EDM) is a variation of EDM process which utilizes a thin wire (around 0.18mm) for material removal. In this article surface roughness in WEDM process was analysed using Taguchi method and experimental results. In experiments it was observed that by increasing the current surface roughness increases and rough surface is produced. Peak current is the most critical parameter having a contribution of 82.12%.

Parameter optimization on WEDM machine of oil hardened nickel (Non – Shrinking) steel

Conventional machining processes find it difficult to machine the hard material. The hard material is machined with wire electrical discharge machining (WEDM). The goal of this research is to machine oil hardened non-shrinking steel using WEDM and to decide on the best possible input variables to maximise the machining performance. The experiment was conducted on the EZEECUT NXG CNC Wire Cut EDM using Taguchi’s L27 orthogonal array. The effects of pulse on time, pulse off time, sensitivity, gap, peak current, and wire feed on material removal rate (MRR) and surface roughness (Ra) are observed. An analysis of variance (ANOVA) was conducted to identify the significance of the machining parameters on the material removal rate and surface roughness. The signal-to-noise ratio generates the characteristics that influence the performance and is used to decide the optimum parameter for maximum performance. The investigational results indicate that pulse on time of 35 µs, pulse off time 07 µs, peak current of 3A, sensitivity 9, gap of 15 mm, and feed rate of 4 mm/min yielded optimal values of surface roughness. The best MRR value is obtained with a pulse on time of 25 µs, a pulse off time of 07 µs, a peak current of 4A, a sensitivity of 10, a gap of 10 mm, and a feed rate of 12 mm/min. The confirmatory test is used to validate the effectiveness of the proposed optimal condition. The results of this study show that variables like pulse on time, pulse off time, and peak current have a big impact on how well a machine works.

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 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.

A New Method of Intraoperative Reposition and Holding of Bone Fragments with Ty-Raps

Background. The quality of fractures reposition in open osteosynthesis is one of the important factors determining the outcome of treatment. Often, the reposition and fixation of bone fragments is not an easy task. The authors propose a method of reposition and temporary fixation of fragments using plastic ty-raps used in electrical work. The aim of the study is to demonstrate the possibilities of new method of intraoperative reposition and fixation of bone fragments using plastic ty-raps. Materials and Methods. Ty-raps were sterilized before the surgery in the modes intended for the preparation of polymer products. After the fragments were dissected, their reposition and fixation are carried out with the help of clamps and bone clamps. At this stage, there is a need for the use of ty-raps, since the bone clamps prevent the plate from laying on the bone. To do this, 3-4 plastic ty-raps were applied to the areas of bone free from bone clamps in the area of the fragments contact. In those places where an intact periosteum and muscles are attached to the fragment, narrow transverse channels in soft tissues are formed with the instrument to wrap the bone with a ty-rap. Then the free end of the ty-rap is passed through its lock and tightened as much as possible. After tightening all the ty-raps, the bone clamps are removed. The applied ty-raps reliably keep the bone fragments from any displacement, even when the segment rotates. A bone plate is placed on the bone surface with tightened ty-raps. Then the plate fixed to the bone with screws. The plate should be placed on the bone without strong pressing, which allows you to remove the ty-raps from under the plate at any stage of osteosynthesis. The ty-raps are removed by cutting them with a scalpel or snacking with wire cutter, then the plate is fixed to the bone with the remaining screws. Conclusion. Ty-raps have many positive properties: they are affordable, cheap, do not lose their mechanical properties after sterilization, allow you to securely hold bone fragments during reposition, X-ray negative. The method has demonstrated convenience and reliability.