Zinc Coated Brass Wire Research Articles

EXPERIMENTAL STUDY ON WIRE ELECTRIC DISCHARGE MACHINING OF NIMONIC 90 USING COATED ELECTRODE

Abstract WEDM machine is an unconventional machine that got accepted in the industries because of its skill to machine any material precisely in the required shape and size. Wire electric discharge machine uses electrical energy to cut hard conductive materials. In the present study, Nimonic 90 a nickel-based superalloy is machined in WEDM using a zinc-coated brass wire electrode to study its surface characteristics and its machinability. Experiments were carried out with central composite design with controllable WEDM factors such as Pulse duration, Servo-voltage, and wire-tension were used to investigate machining performance such as material transfer rate (MRR) and average surface roughness (Ra).The second order quadratic models are developed between WEDM parameters and responses by regression analysis. Analysis of Variance was employed to validate the accuracy of the established statistical models and the impact of the process variables. The RSM based optimization was used to find the optimal process parameter of Wire Tension 11.962 N, Pulse on Time 79.785 µs and Servo Voltage 100 V to achieve maximum MRR of 5.3574 (mm3/min) and minimal Ra of 2.6513 (μm). The validity of the optimized values are verified by conducting confirmation experiments and found that errors are within the permissible limit. Further, the surface morphology of the WEDMed specimen was carried out through SEM to ascertain the mechanisms of material removal under the different settings of WEDM.

THE COMPARATIVE EFFECT OF WIRE ELECTRODES ON WIRE BREAKAGE FREQUENCY AND CUTTING RATE IN WEDM OF INCONEL 706

Non-traditional machining methods like wire electric discharge machining (WEDM) appear to be an ideal choice for machining high strength super alloys like Inconel 706, because of their capability to generate intricate profiles with high accuracy. However, wire breakages are a common problem in the WEDM process and adversely affect the productivity, accuracy, and surface quality. Therefore, the aim of this work is to investigate and comprehend the phenomenon of wire breakage using Inconel 706 as work material and brass wire, diffused brass wire, and zinc-coated brass wire as electrode materials. Six process parameters—pulse-on time, pulse-off time, peak current, spark gap voltage, wire feed rate, and wire tension—have been varied experimentally to determine their effect on the frequency of wire failure. According to the findings, the zinc-coated brass wire breaks with the lowest frequency when compared to the other two. Additionally, an ideal range of input variables has been proposed for efficient WEDM of Inconel 706 without unexpected wire breakages. This range can also be utilized for further research work related to modeling and optimization in WEDM of Inconel 706.

Investigation and optimization of wire EDM process parameters for Al 5454 alloy machining

In the current research, the use of a wire electric discharge machine (WEDM) to machine aluminium 5454 alloy work material is studied. A zinc-coated brass wire with a diameter of 0.25 mm is used as the tool material, and deionized water is used as the dielectric fluid. In this work, different parameters like pulse on time (Ton), current, power, wire feed rate, wire tension, and flushing pressure are varied for analysis of the performance of material removal rate (MRR) and surface roughness (SR). Taguchi L16 is used to design the experiments. Multi-response optimization is done by the multi-response signal-to-noise ratio (MRSN) method to obtain the best combination of parameters. To find the significance of parameters, the Analysis of Variance (ANOVA) technique has been used. From the experimental investigation, it was found that current is the most influential parameter and flushing pressure is the least influential parameter for MRR and SR. The optimal level of input parameters obtained using the optimization method for material removal rate and surface roughness are Peak current = 15A, Pulse on time = 32 s, Wire tension = 15 N, Wire feed = 165 mm/min, Power = 25w, flush pressure = 7 bar. The confirmation experiments are conducted to verify the results obtained by the MSRN method. Optimal WEDM settings for machining Al 5454 alloy samples enhanced improvements in material removal rate and surface finish.

EFFECT OF ZINC COATED BRASS AND LN2 COOLED ZINC COATED BRASS ELECTRODES IN WEDM PERFORMANCE ON INCOLOY

Due to their superior mechanical qualities, such as corrosion resistance and carburization resistance, particularly at high temperatures, nickel-based superalloys are being used more often in the aviation, marine, and nuclear industries. Because of their great strength, low heat conductivity, and strain hardening properties, nickel-based superalloys are particularly difficult to process conventionally. Wire electric discharge machining, one of the non-traditional machining techniques, is utilised in this study to cut Inconel 800. (Incoloy). Wire cut EDM uses electrodes made of zinc-coated brass wire that have been cryogenically chilled. The RSM approach is used to arrange trials using Servo voltage and Wire feed as constant variables and Wire tension, Pulse on time, and Wire feed as changeable factors. In order to maximizes responses, lower is better and higher is better criteria are used to assess material removal and surface roughness for zinc-treated brass and cryogenically chilled (LN2) zinc-treated brass.

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.

Machining Complex Profile on Nickel-Aluminum-Bronze Alloy through Wire Electric Discharge Machining Process using Zinc-Coated Brass Wire

Machining Complex Profile on Nickel-Aluminum-Bronze Alloy through Wire Electric Discharge Machining Process using Zinc-Coated Brass Wire

Surface roughness modeling using machine learning approaches for wire electro-spark machining of titanium alloy

PurposeIn the present study, wire electro-spark machining of Titanium alloy is performed with the machining parameter such as spark-on time, spark-off time, current and servo voltage. The purpose of this study is to model surface roughness using machine learning approach for input/controllable variable. Machined surface examined using scanning electron microscope (SEM) and XRD methods.Design/methodology/approachFull factorial approach has been used to design the experiments with varying machining parameters into three-level four factors. Obtained surface roughness was modeled using machine learning methods namely Gaussian process regression (GPR) and support vector machine (SVM) methods. These methods were compared for both training and testing data with a coefficient of correlation and root mean square error basis. Machined surface examined using scanned electron microscopy and XRD for surface quality produced and check migration of tool material to workpiece material.FindingsMachine learning algorithms has excellent scope for prediction quality response for the wire electric discharge machining (WEDM) process, resulting in saving of time and cost as it is difficult to find each time experimentally. It has been found that the proposed model with minimum computational time, provides better solution and avoids priority weightage calculation by decision-makers.Originality/valueThe proposed modeling provides better predication about surface produced while machining of Ti6Al7Nb using zinc-coated brass wire electrode during WEDM operation.

Study and optimisation of WEDM parameters of AISI P20+Ni using RSM and hybrid deep neural network

ABSTRACTThe main task in Wire Electrical Discharge Machining (WEDM) is to select the proper tool material for machining the workpiece to get better surface finishing and high cutting speed. To overcome these challenges, nowadays, coated electrodes are used. The main objective of this research work is to study the impact of certain input parameters such as pulse off-time, pulse on-time, servo voltage, and peak current in WEDM on Material Removal Rate (MRR), Recast Layer Thickness (RLT), and Surface Roughness (SR) output parameters by using zinc-coated brass wire as an electrode and AISI P20+Ni (DIN 1.2738) as the workpiece. One of the hardest materials used to make die for plastic moulds. The study is carried out experimentally and then compared with the design done by response surface methodology (RSM) using ANOVA and hybrid deep neural network (DNN) predicted values, which are optimised based on Manta ray foraging optimisation (MRFO) to obtain more precise outputs. The developed RSM and hybrid DNN+MRFO were designed in Design Expert 12 and MATLAB R2020a platforms and achieved 90% average prediction accuracy in the DNN+MRFO method. The experimentally obtained maximum MRR and minimum RLT and SR are 2.657 mm3/min, 7.9 µm, and 0.351 µm, respectively. The regression results showed that DNN+MRFO outperforms the RSM model. The achieved desirability at confirmatory analysis for RSM and DNN+MRFO are 0.844 and 0.921, respectively.

Investigation in µ-WEDM of Inconel 625 superalloy using RSM-CCD technique

ABSTRACT Micro wire electric discharge machining (µ-WEDM) has received immense attention due to the tight tolerance requirements of biomedical components and downsizing of sensors. The investigation reports the impact of wire material in machining Inconel 625 superalloy. The quality of machined surface is studied in terms of surface roughness (SR) and erosion rate (ER) by varying the µ-WEDM variables like servo voltage (SV), pulse start time (Tstart), angle of cut (AC), pulse stop time (Tstop) and current (IC). Two different wire electrodes of diameter 150 µm (brass and zinc-coated brass) are used in the study. Machining trials are executed by using central composite design (CCD). Further modeling of responses is carried out using Response Surface Methodology (RSM) and Desirability Analysis (DA) to predict the optimal machining parameters. The zinc-coated brass wire (Wzb) outperforms the plain brass wire (Wb) in terms of machining rate. Servo voltage is identified as a crucial and noteworthy parameter affecting the responses. The SR is decreased by 28.13% at the highest value of SV (70 V), while the ER rose by 41.36% at the minimal value of SV (50 V). The topography of machined surfaces is analyzed using SEM and 3D surface roughness images.

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Ti-6Al-4V is known for its lightweight, high tensile strength, exceptional corrosion resistance, and low thermal coefficient of expansion due to which it finds its application in precision surgical instruments and aeronautical and marine engine parts. In this study, Ti-6Al-4V has been machined using wire EDM machine with two different wire materials. The wire thickness of 0.25 mm heat-treated brass and zinc-coated brass tool and super cool oil as dielectric fluid were utilized for the machining process. Taguchi L9 orthogonal array was used. Ton (Pulse ON time), Toff (Pulse OFF time), wire feed, and Ip (Current) were the input parameters, and the response parameters such as surface roughness (Ra), material removal rate (MRR), tool wear rate (TWR), and recast layer thickness were optimized by TOPSIS optimization. From the results, higher tool wear rate was observed in brass tool. The titanium percentage after machining was found to be 55.05% for zinc-coated brass wire, whereas it was 51.58% for brass wire. Better productivity and surface integrity were observed in zinc-coated brass tool compared to heat-treated brass. MRR increased to 54.93%, surface roughness decreased to 2.40%, recast layer thickness increased to 3.44%, and tool wear rate was increased to 47.96%.

Optimizing WEDM Parameters on Nano-SiC-Gr Reinforced Aluminum Composites Using RSM

Nanocomposites are preferred for performance enhancement over micron composites because of their better performance in enhancing the desired properties of the parent material. Nano-silicon carbide and nano-graphite are considered together for reinforcement of Al7075 in this piece of research. Here, the purpose of reinforcement of graphite considered is to improve machinability. The stir casting was employed for fabrication of nanocomposite. The composite matrix includes Al7075 matrix material, reinforcement material of nano-SiC (5 wt.%), and nano-graphite (5 wt.%). Wire cut Electrical Discharge Machining (WEDM) of the synthesized nanocomposite SiC/Gr/Al7075 is considered for investigating the machinability. The objectives of the study are to synthesize the novel nanocomposite and optimize the process parameters to minimize the kerf width during WEDM. The independent variables like choice of wire electrode including the uncoated brass wire, diffused annealed wire, and zinc coated brass wire were considered along with operating parameters like gap voltage, pulse-off time (Toff), and pulse-on time (Ton). The response surface methodology (RSM) is used for designing experiments and analyzing and optimizing independent parameters of WEDM for minimizing the kerf width. Experimental results reveal that the machinability performance of the novel nanocomposite in WEDM with zinc coated brass wire was the best and produced minimum kerf width with the optimized inputs of 117 μs pulse-on time, 60 μs pulse-off time, 160A input current, and 10 volt gap voltage.

Modeling of Surface Quality and Wire Offset during WEDM of Die Steel D3

The present model portrays the quality of surface machined and wire offset during wire-EDM of Die Steel D3 using zinc-coated brass wire. Taguchi approach is employed, and the orthogonal array was developed using peak current, pulse on duration, and wire tension as the machining parameters. Dependency of wire EDM factors over surface roughness and wire offset was assessed. It was found that the roughness of the machined surface is majorly controlled by on duration of the pulse. For wire offset, the current is the crucial electrical parameter. Higher intensity sparks induce a dimensional shift in the work.

Investigating the parametric effects on wire electric discharge machining performance in processing AA1050-5 wt.% SiC composite with zinc-coated brass wire

Investigating the parametric effects on wire electric discharge machining performance in processing AA1050-5 wt.% SiC composite with zinc-coated brass wire

Effect of different wire materials on WEDM performance of Bio-compatible material

Abstract The present experimental investigation aims to analyse the effect of various machining parameters, such as pulse peak current (Ion), pulse on time (Ton), pulse off time (Toff) and spark voltage (SV) on the surface roughness (SR) and material removal rate(MRR) by using continuous traveling of both wire electrode (i.e. brass wire and zinc-coated brass wire). The present work also analyses the effect of types of wires, such as brass wire and zinc-coated brass wire used during machining of Titanium alloy (Ti-6Al-4V) on Surface roughness (SR) and material removal rate (MRR). This work studies the correlation between various response parameter such SR and MRR by using same machining parameter by for both wires.

Effect of Machining Parameters on Surface Roughness and Metal Removal Rate for AISI 310 L Stainless Steel in WEDM

Wire electrical discharge machining (WEDM) is a non-traditional machining process that is widely used in the machining of conductive materials. This paper presents the investigation on surface roughness and metal removal rate of stainless steel using the wire-cut EDM process. Process input parameters wire feed (WF), wire tension (WT), servo voltage (SV), pulse on time (TON) and pulse off time (Tuff), and the output parameters surface roughness and metal removal rate. The work piece material was used stainless steel 310 L, zinc-coated brass wire of 0.25mm diameter used as a tool and distilled water is used as dielectric fluid. ANOVA used to measure and evaluate the relative importance of different factors. Experiments are designed and analyzed using the factorial design approach. The experimental results revealed that the most important machining parameter of the pulse of time has the most influence on the metal removal rate and the surface roughness. The maximum best metal removal rate is (0.052277 g/min). When the values are somewhat medium range, they are the best and the wire does not break at this range. Wire feed (7m/min), wire tension (7 kef), servo voltage (30 V), TON (30 sic), Tuff (30 sic). The expected values and measured values are well-matched as observed by additional confirmation experiments.

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.

Modeling of kerf width during WEDM of die steel D3

The present model depicts the kerf width during wire-EDM of Die Steel D3 using zinc coated brass wire. Response Surface Methodology with Central Composite Design is employed and orthogonal array was developed using peak current, pulse on time and pulse off time as the machining parameters. Dependency of wire EDM parameters on kerf width was assessed. Micrograph images were taken and measurements were performed in order to assess the value of Kerf Width. It was found that the Kerf Width is majorly influenced by all the three selected electrical parameters. For Kerf Width, peak current is the most crucial electrical parameter. Higher intensity sparks induces dimensional shift in the work. Model validation was performed using point prediction capability of Design Expert. The residual error for Kerf Width was found to be 1.08% thus suggesting suitability of the model.

Influence of machining parameters on surface roughness in wire EDM using zinc coated brass wire

This study discussed the influence of cutting parameters such as (wire feed, wire tension, servo voltage, pulse on time, pulse off time) on surface roughness quality of stainless steel AISI 310 L material as a workpiece in the wire electrical discharge machining process and used Zinc coated brass wire. In order to obtain the best value for surface roughness. In this research four levels of factors affecting the process were used, the values of wire feed (4, 5, 6, and 7) m/min, wire tension (5, 6, 7, and 8) kgf, and servo voltage (20, 30, 40, and 50) Volt, and pulse on time (15, 20, 25, and 30) µsec, pulse off time (30, 40, 50, and 60) µsec. The results showed that the Taguchi method was implemented using the MINITAB 17 program. Experiments proved the best value of surface roughness is obtained was (1.56) µm at experimentally and (1.5461) µm at predictable program. The best values for surface roughness were by using zinc-coated copper wire when at wire feed (6) m/min , wire tension (6) kgf, servo voltage (50) volt, pulse on time (25) µsec, pulse off time (30) µsec. Surface roughness can be predicted using the coefficient determination (R-sq) (94.76 percent).

Investigations on the influence of particle reinforcement and wire materials on the surface quality and machining characteristics of AA6061-TiB2 alloy in WEDM

In this research, the significance of particle reinforcement and the effect of wire materials on machining of AA6061-TiB2 composite by Wire Electrical Discharge Machining (WEDM) was investigated. Stir cast AA6061–TiB2 (varying 5, 10, and 15 wt.%) was used as the work material for this present study owing to its superior mechanical properties and profound applications. WEDM is the most viable cutting process to produce intricate shapes and sharp corners with good surface texture. Taguchi methodology was used to conduct the experiments. Phase constituents of the work material were observed using XRD analysis. The results revealed that aluminium and titanium diboride are the major phase constituents without any reaction phases. Metallographic analysis was conducted to figure out the erosion mechanism and crater formation during spark discharge. The experimentation reveals that the percentage of particle reinforcement was the dominating factor in surface quality (62.04%) and machinability (34.2%). The TiB2 (5 wt.%) reinforced composite exhibits excellent machinability and surface quality. Furthermore, in terms of machining rate, zinc-coated brass wire performs better than plain brass wire. Contrastingly, plain brass wire exhibits superior surface quality. In addition to that multi-objective optimization was performed using desirability analysis to achieve higher material removal rate and lower surface roughness. After the confirmation test, it is seen that the experimental values are in close agreement with the estimated values.

Experimental investigation on WEDM performance analysis using grey-fuzzy integrated with TLBO algorithm for Inconel 625: comparison with GA and SA

Purpose In the present study, wire electro-discharge machining (WEDM) of Inconel 625 (In-625) is performed with the machining parameter such as spark-on time, spark-off time, wire-speed, wire tension and servo voltage. The purpose of this study is to find the most favorable machining parameter setting with respect to WEDM performance such as material removal rate (MRR) and surface roughness (RA). Design/methodology/approach Taguchi’s L27 orthogonal array has been used to design the experiments with varying machining parameters into three-level four factors. A hybrid multi-optimization technique has been purposed with grey relation analysis and fuzzy inference system integrated with teaching learning-based optimization to achieve optimum machinability (MRR and RA in present case). The obtained result has been compared with two evolutionary optimization tools via a genetic algorithm and simulated annealing. Findings It has been found that proposed hybrid technique taking minimum computational time, provide better solution and avoid priority weightage calculation by decision-makers. A confirmation test has been performed at single and multi-optimal parameter settings. The decision-makers have been chosen to select any single or multi-parameter setting as per the industry’s demand. Originality/value The proposed optimization technique provides better machinability of In-625 using zinc-coated brass wire electrode during WEDM operation.