Wire electrical discharge machining (WEDM) is a non conventional machining process which is widely used in machining of conductive materials.The applications of WEDM are in automobiles, aero-space, medical instruments, tool and die industries. in the present study analysis of effect of various control factors like Ton,Toff,Sv,Ip,Wf,Wt on checking the cutting rate of S7 steel is studied by using wire cut EDM and one factor time approach.S7 steels contain less carbon and higher toughness than the high carbon types that are more wear resistant. Shock resistant steels are used where heavy cutting or forming operations is required and chipping or breakage of high-carbon wear-resistant steels is a problem. The other big advantage of this study is to select the range of significant control factors for final experimentation.
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
This paper discuss of literature review of EDM and ANNOVA Technology used in on CNC. Today CNC technology has major contribution in i ndustries. CNC machines are main platform in the contribution of good quality products in industries. Basically CNC machines are automated operating machines which are based on code letters,numbers and special characters. The numerical data required for manufacturin g a part provided by machine is called CNC (Computer Numerical Controlled). To remain successful in today�s competitive market,the manufacturers should rely on their Engineer s and production professionals for quick and effective manufacturing setup and also to achie ve Quality products. The machining process on a CNC Milling is programmed by speed,feed rate,and cutting depth,which are frequently determined based on the job s hop experiences However,the machine performance and the product characteristics are not guaranteed to be acceptable.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
This document describes research into optimizing the surface roughness of EN 1010 low alloy steel using wire electrical discharge machining (WEDM). Experiments were conducted using a central composite design to investigate the effects of four process parameters (pulse on time, pulse off time, peak current, and servo voltage) on surface roughness. Analysis of variance was used to identify significant parameters and develop a mathematical model relating the parameters to surface roughness. The model achieved a good fit to the data and can be used to determine the optimal parameter settings that minimize surface roughness.
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
This paper discuss of literature review of EDM and ANNOVA Technology used in on CNC. Today CNC technology has major contribution in i ndustries. CNC machines are main platform in the contribution of good quality products in industries. Basically CNC machines are automated operating machines which are based on code letters,numbers and special characters. The numerical data required for manufacturin g a part provided by machine is called CNC (Computer Numerical Controlled). To remain successful in today�s competitive market,the manufacturers should rely on their Engineer s and production professionals for quick and effective manufacturing setup and also to achie ve Quality products. The machining process on a CNC Milling is programmed by speed,feed rate,and cutting depth,which are frequently determined based on the job s hop experiences However,the machine performance and the product characteristics are not guaranteed to be acceptable.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
This document describes research into optimizing the surface roughness of EN 1010 low alloy steel using wire electrical discharge machining (WEDM). Experiments were conducted using a central composite design to investigate the effects of four process parameters (pulse on time, pulse off time, peak current, and servo voltage) on surface roughness. Analysis of variance was used to identify significant parameters and develop a mathematical model relating the parameters to surface roughness. The model achieved a good fit to the data and can be used to determine the optimal parameter settings that minimize surface roughness.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
OPTIMIZATIONS OF MACHINING PARAMETER IN WIRE EDM FOR 316L STAINLESS STEEL BY ...IAEME Publication
WEDM is one of the non-traditional method used for the machining complex shape structure and components made up of hard material like composites and HSS. This is an experimental investigation of wire electro-discharge machining (WEDM) of 316L SS. The outstanding characteristics of stainless steel 316L such as their compatibility and noticeable physical, mechanical and biological performance has led to increased application of them in various industries especially in biomedical industries over the last 50 years.316L SS is used extensively for weldments where its immunity to carbide precipitation due to welding assures optimal corrosion resistance. There are some difficulties in machining of stainless steel by conventional machining. On the other hand, unconventional machining process especially Wire electrical discharge machining (WEDM) are more appropriate techniques for machining difficult to machine materials such as stainless steel.
The document describes a study that developed an artificial neural network (ANN) model to predict surface roughness, cutting force, and temperature during machining of Nimonic-75 and Nicrofer C-263 super alloys. Experiments were conducted to collect input/output data on cutting speed, feed rate, depth of cut, surface roughness, cutting force, and temperature. The ANN model was trained on this data and could accurately model the complex relationships between cutting conditions and output parameters for process analysis and optimization.
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
Parameter Optimization of Wire EDM in a Range of Thickness for EN8 Die SteelIJTET Journal
Wire Electrical Discharge Machining (WEDM) is also known as an electro thermal production process in then, nor
electricity) allows the wire to cut through the metal by the use of heat from electrical sparks. The present work process approach
to parameter optimization in wire electric discharge machining of EN-8 die steel (of thickness 50 and 75mm) using Taguchi
method which optimizes four process parameters (factors) such as pulse ON time, pulse OFF time, current, voltage and two
important response such as material removal rate (MRR) and in surface roughness (Ra –average roughness) of machined
workpiece is considered in this study. Taguchi is an efficient search technique, is used to obtain the optimal setting of the desired
responses and to avoid the conflicting nature of response. Taguchi designs focus on reducing variability, as well as setting the mean to target.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Review Article on Machining of Nickel-Based Super Alloys by Electric Discharg...sushil Choudhary
Electric discharge machining (EDM) process generally used for burrs free, less metallurgical damage, stress free and very precise machining and produces mould cavity, deep holes, complex shapes & size by arc erosion in all types of electro-conductive materials. In this process, the metal is removed from the work piece due to erosion caused by rapidly recurring spark discharge taking place between the tool electrode and work-piece. Tool electrode and wok-piece both submersed into the dielectric fluid. The main aims of this review paper work is to present the consolidated information about the contribution of various researchers on the machining applications of electric discharge machining process on Nickel-Base Super alloys materials, utilization of various tool and techniques for correlating experiment results and applications of product through the EDM. Nickel-Base Super alloys materials is widely used for fuel tanks, aircraft & rocket engine components, nuclear fuel element spacers, casings, fasteners, rings, seal, measuring instrument, cryogenic storage tanks and automobile components etc.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Experimental Investigation and Multi Objective Optimization for Wire EDM usin...IRJET Journal
This document discusses using Taguchi's method to optimize the wire electrical discharge machining (EDM) process. Experiments were conducted using AISI D3 tool steel workpieces of varying thickness. Process parameters like peak current, pulse on/off times were varied. Taguchi's method was used to analyze the effects of parameters on responses like surface roughness, material removal rate, and wire wear ratio. The method identified optimized parameter sets that produced the highest material removal rate, lowest surface roughness, and lowest wire wear ratio for different workpiece thicknesses. Confirmation experiments showed errors within 7-8%, validating the optimized parameters. The study demonstrated using multi-objective optimization and Taguchi's method to improve multiple EDM machining
The document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
This document describes a framework developed using Taguchi methods to optimize two quality characteristics, surface roughness and angular accuracy, in wire electrical discharge machining (W-EDM) operations. An experiment was conducted using an L9 orthogonal array to investigate the effects of four controllable factors (pulse on time, feed rate, voltage, and wire tension), each at three levels, on the two response variables. The optimal settings identified were able to improve both surface roughness and angular accuracy, as confirmed through additional validation experiments. This research established a systematic approach for obtaining a single optimal parameter setting to maximize multiple quality characteristics simultaneously in machining applications.
IRJET- The Process of Edm Cutting Parameters Optimizing by using Taguchi Meth...IRJET Journal
The document discusses optimizing the parameters for wire electrical discharge machining (EDM) of Inconel 718 using the Taguchi method and analysis of variance (ANOVA). It aims to determine the optimal settings for wire feed rate, pulse on time, pulse off time, peak current, and servo voltage to maximize material removal rate, minimize kerf width and surface roughness. Experiments were conducted using two different wire materials - half hard brass wire and zinc-coated brass wire. The results showed that zinc-coated brass wire achieved a higher material removal rate and better surface finish compared to half hard brass wire. However, half hard brass wire produced a smaller kerf width. ANOVA was used to analyze the experimental data and determine the
IRJET-Experimental Analysis Optimization of Process Parameters of Wire EDM on...IRJET Journal
This document analyzes the optimization of process parameters for wire electrical discharge machining (WEDM) of stainless steel 316L. It conducts experiments using different controllable factors like discharge current, pulse on/off time, and arc gap. Taguchi design of experiments is used to optimize for maximum material removal rate. Experiments are conducted using a copper tool on 316L stainless steel workpieces. The results are analyzed to determine the optimum parameter levels for achieving higher material removal rate and better surface finish quality during WEDM of 316L stainless steel.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
OPTIMIZATIONS OF MACHINING PARAMETER IN WIRE EDM FOR 316L STAINLESS STEEL BY ...IAEME Publication
WEDM is one of the non-traditional method used for the machining complex shape structure and components made up of hard material like composites and HSS. This is an experimental investigation of wire electro-discharge machining (WEDM) of 316L SS. The outstanding characteristics of stainless steel 316L such as their compatibility and noticeable physical, mechanical and biological performance has led to increased application of them in various industries especially in biomedical industries over the last 50 years.316L SS is used extensively for weldments where its immunity to carbide precipitation due to welding assures optimal corrosion resistance. There are some difficulties in machining of stainless steel by conventional machining. On the other hand, unconventional machining process especially Wire electrical discharge machining (WEDM) are more appropriate techniques for machining difficult to machine materials such as stainless steel.
The document describes a study that developed an artificial neural network (ANN) model to predict surface roughness, cutting force, and temperature during machining of Nimonic-75 and Nicrofer C-263 super alloys. Experiments were conducted to collect input/output data on cutting speed, feed rate, depth of cut, surface roughness, cutting force, and temperature. The ANN model was trained on this data and could accurately model the complex relationships between cutting conditions and output parameters for process analysis and optimization.
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
Parameter Optimization of Wire EDM in a Range of Thickness for EN8 Die SteelIJTET Journal
Wire Electrical Discharge Machining (WEDM) is also known as an electro thermal production process in then, nor
electricity) allows the wire to cut through the metal by the use of heat from electrical sparks. The present work process approach
to parameter optimization in wire electric discharge machining of EN-8 die steel (of thickness 50 and 75mm) using Taguchi
method which optimizes four process parameters (factors) such as pulse ON time, pulse OFF time, current, voltage and two
important response such as material removal rate (MRR) and in surface roughness (Ra –average roughness) of machined
workpiece is considered in this study. Taguchi is an efficient search technique, is used to obtain the optimal setting of the desired
responses and to avoid the conflicting nature of response. Taguchi designs focus on reducing variability, as well as setting the mean to target.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Review Article on Machining of Nickel-Based Super Alloys by Electric Discharg...sushil Choudhary
Electric discharge machining (EDM) process generally used for burrs free, less metallurgical damage, stress free and very precise machining and produces mould cavity, deep holes, complex shapes & size by arc erosion in all types of electro-conductive materials. In this process, the metal is removed from the work piece due to erosion caused by rapidly recurring spark discharge taking place between the tool electrode and work-piece. Tool electrode and wok-piece both submersed into the dielectric fluid. The main aims of this review paper work is to present the consolidated information about the contribution of various researchers on the machining applications of electric discharge machining process on Nickel-Base Super alloys materials, utilization of various tool and techniques for correlating experiment results and applications of product through the EDM. Nickel-Base Super alloys materials is widely used for fuel tanks, aircraft & rocket engine components, nuclear fuel element spacers, casings, fasteners, rings, seal, measuring instrument, cryogenic storage tanks and automobile components etc.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Experimental Investigation and Multi Objective Optimization for Wire EDM usin...IRJET Journal
This document discusses using Taguchi's method to optimize the wire electrical discharge machining (EDM) process. Experiments were conducted using AISI D3 tool steel workpieces of varying thickness. Process parameters like peak current, pulse on/off times were varied. Taguchi's method was used to analyze the effects of parameters on responses like surface roughness, material removal rate, and wire wear ratio. The method identified optimized parameter sets that produced the highest material removal rate, lowest surface roughness, and lowest wire wear ratio for different workpiece thicknesses. Confirmation experiments showed errors within 7-8%, validating the optimized parameters. The study demonstrated using multi-objective optimization and Taguchi's method to improve multiple EDM machining
The document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
This document describes a framework developed using Taguchi methods to optimize two quality characteristics, surface roughness and angular accuracy, in wire electrical discharge machining (W-EDM) operations. An experiment was conducted using an L9 orthogonal array to investigate the effects of four controllable factors (pulse on time, feed rate, voltage, and wire tension), each at three levels, on the two response variables. The optimal settings identified were able to improve both surface roughness and angular accuracy, as confirmed through additional validation experiments. This research established a systematic approach for obtaining a single optimal parameter setting to maximize multiple quality characteristics simultaneously in machining applications.
IRJET- The Process of Edm Cutting Parameters Optimizing by using Taguchi Meth...IRJET Journal
The document discusses optimizing the parameters for wire electrical discharge machining (EDM) of Inconel 718 using the Taguchi method and analysis of variance (ANOVA). It aims to determine the optimal settings for wire feed rate, pulse on time, pulse off time, peak current, and servo voltage to maximize material removal rate, minimize kerf width and surface roughness. Experiments were conducted using two different wire materials - half hard brass wire and zinc-coated brass wire. The results showed that zinc-coated brass wire achieved a higher material removal rate and better surface finish compared to half hard brass wire. However, half hard brass wire produced a smaller kerf width. ANOVA was used to analyze the experimental data and determine the
IRJET-Experimental Analysis Optimization of Process Parameters of Wire EDM on...IRJET Journal
This document analyzes the optimization of process parameters for wire electrical discharge machining (WEDM) of stainless steel 316L. It conducts experiments using different controllable factors like discharge current, pulse on/off time, and arc gap. Taguchi design of experiments is used to optimize for maximum material removal rate. Experiments are conducted using a copper tool on 316L stainless steel workpieces. The results are analyzed to determine the optimum parameter levels for achieving higher material removal rate and better surface finish quality during WEDM of 316L stainless steel.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
Optimization of machining parameters in edm of cfrp composite using taguchi t...IAEME Publication
1. The document summarizes a study that used Taguchi methods to optimize machining parameters for electrical discharge machining (EDM) of carbon fiber reinforced plastic (CFRP) composite material.
2. The study investigated the effects of gap voltage, discharge current, and pulse-on time on surface roughness. Experiments were conducted using an L9 orthogonal array.
3. Analysis of variance (ANOVA) and signal-to-noise ratios were used to analyze the results. It was found that discharge current had the most significant influence on surface roughness, and confirmation experiments validated the optimum parameters identified.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
This document analyzes the effect of different wire electrodes on the material removal rate (MRR) of an MS workpiece using wire electrical discharge machining (WEDM). Experiments were conducted using copper, brass, and zinc-coated brass wire electrodes at various levels of current and pulse duration. The results showed that MRR was highest with copper wire and decreased with brass and zinc-coated brass wires. MRR also decreased with increasing current but increased with longer pulse duration. Statistical analysis through ANOVA confirmed that the wire material and pulse duration significantly affected the MRR while current had a lesser effect.
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
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Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9µs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13µs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1µin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICRO...ijiert bestjournal
Nowadays,necessity of small components is a common trend. These requirements encourage the researcher s to develop very minutest size components to fulfill the demand. The manufact uring of these type of components is a difficult ob ligation and for that various machining methods are develop to manufacture such c omponents. In this article the Electro Chemical mac hining and Electrical Discharge Machining is reviewed. We tried to summar ize the work of various researchers. The study show s that this type of machining processes gives good alternative.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
This document summarizes research that used response surface methodology to optimize the electrical discharge machining (EDM) process parameters when machining SCM420 low alloy steel. The researchers investigated the effects of peak current, pulse on time, and gap voltage on material removal rate (MRR) and surface roughness (Ra). They conducted experiments according to a central composite design and analyzed the results to develop mathematical models relating the process parameters to the output responses. The analysis found that peak current had the greatest influence on both MRR and Ra, with MRR increasing and Ra decreasing at higher peak current levels. Optimal values for the process parameters to achieve high MRR and low Ra were determined to be a peak current of 22 amps, pulse
Optimization of Cutting Rate for EN 1010 Low Alloy Steel on WEDM Using Respon...IJAEMSJORNAL
The document describes an experiment to optimize cutting rate (CR) when machining EN 1010 low alloy steel using wire electric discharge machining (WEDM). Central composite design was used to plan experiments varying pulse on time, pulse off time, peak current, and servo voltage. 21 experiments were conducted and the average CR was measured for each. Response surface methodology was applied to develop a model relating the process parameters to CR. Analysis of variance showed the quadratic model adequately described the relationship with an R2 of 0.970641. An empirical equation was derived to predict optimal CR based on settings of the four process parameters.
Process Parameter Optimization of WEDM for AISI M2 & AISI H13 by Anova & Anal...IJERA Editor
The document summarizes a study on optimizing process parameters for wire electrical discharge machining (WEDM) of AISI M2 and AISI H13 steel alloys. Experiments were conducted using a Taguchi L16 orthogonal array with peak current, pulse on time, pulse off time, and workpiece material as parameters. Responses measured included material removal rate, surface roughness, kerf width, and spark gap. ANOVA showed peak current and pulse on time most significantly affected responses. For AISI M2, low peak current, short pulse on and off times minimized surface roughness and kerf width while maximizing material removal rate. For AISI H13, low peak current, long pulse on time
Multi-Objective Optimization of EDM process parameters using Taguchi-Grey Rel...IRJET Journal
This document presents a study that uses Taguchi-Grey Relational Analysis to optimize the EDM process parameters for aluminum work material with a copper electrode. The objectives are to maximize the material removal rate and minimize the tool wear rate and surface roughness. Experiments are conducted with four machining parameters (discharge current, pulse on time, flushing pressure, and polarity) each at two levels. Response data is analyzed using Grey Relational Analysis to determine the optimal parameter combination and ranking. The optimal levels found are discharge current of 16A, pulse on time of 1010 μs, flushing pressure of 5kgf/cm2, and normal polarity. Analysis of variance indicates that discharge current has the most significant influence on the output responses
This document provides a review of optimization techniques for the wire electrical discharge machining (WEDM) process. It begins with an introduction to WEDM, describing the working principle and important process parameters like pulse width, time between pulses, servo reference voltage, and wire tension. The document then reviews literature on optimization methods that have been used to maximize material removal rate while minimizing electrode wear rate. Specifically, it discusses two studies that used Taguchi's design of experiments approach and desirability functions to optimize cutting conditions for different materials like minimizing wear rate and maximizing material removal rate in WEDM.
A Review Study On Optimisation Of Process Of Wedm And Its DevelopmentIOSR Journals
This document provides a review of optimization techniques used to improve the process of wire electrical discharge machining (WEDM). It begins with an abstract summarizing the paper's focus on developing and optimizing WEDM processes. The introduction discusses key aspects of WEDM like operating parameters, material removal rate, surface finish, and electrode wear rate. It also outlines the working principle and a diagram of the WEDM process. The literature survey section summarizes several past studies that optimized WEDM parameters like pulse on/off time and current using techniques like the Taguchi method and response surface methodology. The conclusion is that more research could optimize parameters and responses for different materials and tool materials.
OPTIMIZATION OF MACHINING PARAMETERS IN EDM OF CFRP COMPOSITE USING TAGUCHI T...IAEME Publication
Electrical discharge machining (EDM) is a nontraditional manufacturing technique that has been widely used in the production of tools and dies throughout the world in recent years. The most important performance measure in EDM is the surface roughness. In this study, the effect and
optimization of machining parameters on surface roughness in an EDM operation was investigated by using the Taguchi method. The experimental studies were conducted under varying gap voltage,discharge current, and pulse-on time
Optimization of machining parameters in edm of cfrp composite using taguchi t...IAEME Publication
This document summarizes a study that used the Taguchi method to optimize machining parameters for electrical discharge machining (EDM) of carbon fiber reinforced plastic (CFRP) composite material. The goal was to minimize surface roughness. Experiments were conducted varying gap voltage, discharge current, and pulse-on time. An L9 orthogonal array was used to design the experiments. Surface roughness measurements were analyzed using signal-to-noise ratios and analysis of variance to determine the most influential factors. The results showed that discharge current had the largest effect on surface roughness. Confirmation experiments validated that the optimal parameters produced results consistent with predictions.
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ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR S7 STEEL
1. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
57
ANALYSIS AND STUDYTHE
EFFECTSOFVARIOUS CONTROL FACTORS OF
CNC-WIRE CUT EDMFOR S7 STEEL
SonuDhiman 1
, RavinderChaudhary2
, V.K.Pandey3
1
Post Graduate student in Industrial And Production Engg. at SKIET, Kurukshetra.
2
Assistant Professor in Mechanical at SKIET, Kurukshetra.
3
Director at SKIET, Kurukshertra.
Abstract
Wire electrical discharge machining (WEDM) is a non conventional machining process which is widely
used in machining of conductive materials.The applications of WEDM are in automobiles, aero-space,
medical instruments, tool and die industries. in the present study analysis of effect of various control
factors like Ton,Toff,Sv,Ip,Wf,Wt on checking the cutting rate of S7 steel is studied by using wire cut EDM
and one factor time approach.S7 steels contain less carbon and higher toughness than the high carbon
types that are more wear resistant. Shock resistant steels are used where heavy cutting or forming
operations is required and chipping or breakage of high-carbon wear-resistant steels is a problem. The
other big advantage of this study is to select the range of significant control factors for final
experimentation.
Key words :
Wire Electric discharge machining (WEDM) , OFAT (one factor time approach),S7 steel, Control Factors
(like Pulse On-Time, pulse off time, Peak Current, servo voltage, wire feed and wire tension), Cutting rate
(CR).
1.Introduction
Wire Electrical Discharge Machining (Wire-EDM) is an electro thermal production process in
which a thin single strand metal wire in conjunction with de-ionized water (used to conduct
electricity) allows the wire to cut through metal by the use of heat from electrical sparks. Due to
the inherent properties of the process, wire EDM can easily machine complex parts and precision
components out of hard conductive materials. Electrical discharge machining is frequently used
to make dies and moulds conductive. The working principle of wedm is as shown in figure below.
2. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
58
Fig 1.1: Mechanism Of Material Removal In Wedm
Tosun et al. voltage, wire speed and dielectric fluid pressure was experimentally investigated in
WEDM. Brass wire with 0.25 mm diameter and SAE 4140 steel with 10 mm thickness were used
as tool and work-piece materials in the experiments, respectively. It is found experimentally that
the increasing pulse duration, open circuit voltage and wire speed, increase the surface roughness
whereas the increasing dielectric fluid pressure decreases the surface roughness. The variation of
work-piece surface roughness with machining parameters is modelled by using a power function.
The level of importance of the machining parameters on the work-piece surface roughness is
determined by using analysis of variance (ANOVA).Yan and huang et al improved the
machining accuracy by a closed-loop wire tension control system for a wire-EDM. PI controller
and one-step-ahead adaptive controller are employed to investigate the dynamic performance of
the closed-loop wire tension control system. In order to reduce the vibration of wire-tension
during wire feeding, dynamic absorbers are added to the idle rollers of wire transportation
mechanism. Experimental results indicate that the geometrical contour error of corner cutting is
reduced with approximately 50% and the vertical straightness of a work-piece can be improved
significantly. scott f. Miller et al Studied the WEDM of cross-section with minimum thickness
and compliant mechanisms. Effects of EDM process parameters, particularly the spark cycle time
and spark on-time on thin cross-section cutting of Nd–Fe–B magnetic material, carbon bipolar
plate, and titanium are investigated. An envelope of feasible wire EDM process parameters is
generated for the commercially pure titanium. The application of such envelope to select suitable
EDM process parameters for micro feature generation is demonstrated. Scanning electron
microscopy (SEM) analysis of EDM surface, subsurface, and debris are presented.Huang and
Chang et al displayed the surface alloying behaviour of tempered martensitic stainless steel
multi-cut with WEDM. Before machined with WEDM, the steel specimens were quenched at
1050 C and then tempered at 200 C, 400 C, and 600 C, respectively. The microstructure and
surface morphology of the multi-cut surfaces were examined with scanning and transmission
electron microscopes integrated with an energy-dispersive X-ray spectrometer for chemical
composition analysis. N.M. Abbas and bahari et al. studied that EDM process is based on
thermoelectric energy between the work piece and an electrode. A pulse discharge occurs in a
small gap between the work piece and the electrode and removes the unwanted material from the
parent metal through melting and vaporizing. The electrode and the work piece must have
electrical conductivity in order to generate the spark. mohammadi and karimi et at. The setting
of machining parameters relies strongly on the experience of operators and machining parameter
tables provided by machine tool builders. It is difficult to utilize the optimal functions of a
machine owing to there being too many adjustable machining parameters.H.Singh and
RohitGarg et al. found that the material removal rate (MRR) directly increases with increase in
pulse on time and peak current while decreases with increase in pulse off time and servo voltage.
They used ELECTRONICA SPRINTCUT WEDM as a machine tool and hot die steel (H-11) as
work-piece. Jangrakamal et al presented the optimization of performance characteristics in
WEDM using Taguchi Grey relational analysis. Process parameters were investigated using
mixed L orthogonal array.GRA was applied to determine optimal L18 process parameters for
3. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
59
optimization of multiple performance characteristics which were investigated during rough
cutting operation in D-3 tool steel. U.Natarajan and yang et al. focuses RSM for the multiple
response optimization in micro-endmilling operation to achieve maximum metal removal rate
(MRR) and minimum surface roughness. Aluminium block of 60×40×16 mm is used as the
workpiece material and carbide endmill cutter of diameter 1 mm as the cutting tool. N.Sharma
and R. Sharma et al. optimized the process parameters for the cutting speed and dimensional
deviation for high strength low alloy steel (HSLA) on WEDM. Response surface methodology
was used for the modelling and multi-response optimization.
1.1 EXPERIMENTAL DETAIL
WEDM machine (S-35, Sparkonix) was used as the experimental machine in this study. A Brass
Wire with a diameter of 0.025 mm was used as an electrode to erode a work piece of S7 STEEL
(flat plate). The gap between work piece and electrode was flooded with a moving dielectric
fluid.
Fig 1.2: pictorial view of wedmmachin
Fig.1.3 shows the arrangement of work piece during pilot experimentation
Fig 1.3: pilot experimentation
For WEDM, cutting rate is a desired characteristic and it should be as high as possible to give
minimum machine cycle time leading to increased productivity. In the present study cutting rate
and is mainly measures for a evaluation of job.the cutting which is directly displayed on the
screen of the machine and is given units is inmm/min (Figure 1.4).
Figure 1.4: Set Up for Cutting Rate and Measurement
The purpose of the pilot experiments is to study the various changes of the WEDM control factors
on performance measures such as Cutting Rate.
Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
59
optimization of multiple performance characteristics which were investigated during rough
cutting operation in D-3 tool steel. U.Natarajan and yang et al. focuses RSM for the multiple
response optimization in micro-endmilling operation to achieve maximum metal removal rate
(MRR) and minimum surface roughness. Aluminium block of 60×40×16 mm is used as the
workpiece material and carbide endmill cutter of diameter 1 mm as the cutting tool. N.Sharma
and R. Sharma et al. optimized the process parameters for the cutting speed and dimensional
deviation for high strength low alloy steel (HSLA) on WEDM. Response surface methodology
was used for the modelling and multi-response optimization.
1.1 EXPERIMENTAL DETAIL
WEDM machine (S-35, Sparkonix) was used as the experimental machine in this study. A Brass
Wire with a diameter of 0.025 mm was used as an electrode to erode a work piece of S7 STEEL
(flat plate). The gap between work piece and electrode was flooded with a moving dielectric
fluid.
Fig 1.2: pictorial view of wedmmachin
Fig.1.3 shows the arrangement of work piece during pilot experimentation
Fig 1.3: pilot experimentation
For WEDM, cutting rate is a desired characteristic and it should be as high as possible to give
minimum machine cycle time leading to increased productivity. In the present study cutting rate
and is mainly measures for a evaluation of job.the cutting which is directly displayed on the
screen of the machine and is given units is inmm/min (Figure 1.4).
Figure 1.4: Set Up for Cutting Rate and Measurement
The purpose of the pilot experiments is to study the various changes of the WEDM control factors
on performance measures such as Cutting Rate.
Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
59
optimization of multiple performance characteristics which were investigated during rough
cutting operation in D-3 tool steel. U.Natarajan and yang et al. focuses RSM for the multiple
response optimization in micro-endmilling operation to achieve maximum metal removal rate
(MRR) and minimum surface roughness. Aluminium block of 60×40×16 mm is used as the
workpiece material and carbide endmill cutter of diameter 1 mm as the cutting tool. N.Sharma
and R. Sharma et al. optimized the process parameters for the cutting speed and dimensional
deviation for high strength low alloy steel (HSLA) on WEDM. Response surface methodology
was used for the modelling and multi-response optimization.
1.1 EXPERIMENTAL DETAIL
WEDM machine (S-35, Sparkonix) was used as the experimental machine in this study. A Brass
Wire with a diameter of 0.025 mm was used as an electrode to erode a work piece of S7 STEEL
(flat plate). The gap between work piece and electrode was flooded with a moving dielectric
fluid.
Fig 1.2: pictorial view of wedmmachin
Fig.1.3 shows the arrangement of work piece during pilot experimentation
Fig 1.3: pilot experimentation
For WEDM, cutting rate is a desired characteristic and it should be as high as possible to give
minimum machine cycle time leading to increased productivity. In the present study cutting rate
and is mainly measures for a evaluation of job.the cutting which is directly displayed on the
screen of the machine and is given units is inmm/min (Figure 1.4).
Figure 1.4: Set Up for Cutting Rate and Measurement
The purpose of the pilot experiments is to study the various changes of the WEDM control factors
on performance measures such as Cutting Rate.
4. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
60
The pilot experiments were performed on ELECTRONICA make SPRINTCUT 734 WEDM
machine. Various input control factors varied during the experimentation are pulse on time, pulse
off time, spark gap voltage, peak current, wire tension, wire feed. Apart from the parameters
mentioned above following parameters were kept constant at a fixed value during the
experimentation.
Work piece : S7 Steel
Electrode (tool) : 0.25mmØ
Work piece height : 12mm
Cutting length : 78 mm
Dielectric Conductivity : 20mho
Dielectric temperature : 20-240C
2. Experimental set up & Methodology
The purpose of this study is analysing the effect of WEDM process parameters on response
variable such as Cutting Rate. Also, it is intended to ascertain the ranges of different parameters
required for the experimental design methodology used in this work. Investigation of the working
range of the WEDM process parameters using one factor at a time approach (OFAT).i.e. fixing
some parameters and vary individual parameters one by one with the response variable (cutting
rate).
Effect of various control factors are analysed by performing various experiments with variation of
input parameters.First observation is made to check the Effect of Pulse on Time on Response
Variable as:
3. Result and Discussion
In the first set of experiment: - The pulse on time (Ton) is varied from 100 machine units to 131
machine units. The values of the other control factors are given as Toff = 31 unit; IP= 115 A SV
=50V WT = 8 machine units; WF = 8 m/min; and SF = 2100 unit. The experimentally observed
values of the response variables for different values of pulse on time are given in Table 1.1 The
scatter plots of pulse on time versus response variables are shown in Figure 1.5.
Table 1.1 Experimental value of Ton vs CR
Range: (100-131)
Pulse on
Time
(µs)
Cutting
Rate
(mm/min)
100 0.73
104 1.03
116 2.05
120 2.09
128 2.3
5. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
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Figure 1.5: Effect of Pulse on Time on Cutting Rate.
The cutting rate increases with the increase in the pulse on time. This is due to the fact that with
the increase in pulse on time the discharge energy increases, due to which CS increases also with
the increase of Ton machining time increase. These findings are in agreement with some of
researchers [Tarng, Y. S., Ma, S. C., Chung, L. K. (1995)].
In the second set of experiments: the pulse off time (Toff) is varied from 0 machine units to 60
machine units. The values of the other control factors are given as Ton = 116 unit; IP= 115 A SV
=50V WT = 8 machine units; WF = 8 m/min; and SF = 2100 unit. The experimentally observed
values of the response variables for different values of pulse off time are given in Table 1.2 The
scatter plots of pulse off time versus response variables are shown in Figure 1.6.
Table 1.2:Effect of Pulse OFF Time on CR
Range (0-60)
Pulse
off
Time
(µs)
Cutting
Rate
(mm/min)
10 2.45
15 2.33
31 2.12
40 1.44
46 0.87
Figure 1.6: Effect of Pulse off Time on Cutting Rate.
With the increase in pulse off time, the cutting rate decreases. Due to decrease in spark energy.
These findings are in agreement with some of researchers [Gwo-LianqChern and Ying-
JengEngin in 2007].
In the third set of experiments: Effect of peak Current on Response Variable is calculated by
considering following values:
The Peak Current is varied from 100 units to 200 units. The values of the other control factors are given as
Ton=116 unit; Toff=31 unit, SV =50 V, WF=8 m/min, WT=8 machine unit and SF=2100 unit. The
experimentally observed values of the response variables for different values of peak current are given in
Table 1.3 The scatter plots of Peak Current versus response variables are shown in Figure 1.7
6. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
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Table 1.4: Effect of Peak Current on CR
Range: (0-230)
Peak
Current
Cutting
Rate
(mm/min)
100 0.63
110 1.13
120 2.52
140 2.96
180 3.2
Figure 1.7: Effect of Peak current on Cutting Rate.
It has been observed that as the Peak current increases the value of cutting rate This is in line with
one of the researcher [Gwo-LianqChern and Ying-JengEngin IN 2007].
In the fourth set of experiments: In the fourth set of experiments, the servo voltage is varied
from 30 units to 85 units. The values of the other control factors are given as Ton = 116 unit; Toff
= 31 A Ip = 115 A ;Wt = 8 machine unit ,Wf = 8 machine unit, SF = 2100 unit. The
experimentally observed values of the response variables for different values of Servo voltage are
given in Table 1.4 The scatter plots of pulse on time versus response variables are shown in
Figure 1.8.
Table 1.5: Effect of Serco voltage on CR
Range (0-99)
Servo
voltage
(SV)
Cutting
Rate
(mm/min)
30 2.18
35 2.12
50 2.04
60 1.58
70 1.39
7. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
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Figure 1.8: Effect of servo voltage on Cutting Rate
.
It is observed that as the value of servo voltage increases, the value of cutting rate
increases[Tarang et al (1994)].
In fifth set of experiments:The wire feed is varied from 7 units to 9 units.The values of the other
control factors are given as Ton = 116 unit; Toff = 31,Ip= 115 A: SV =50V; WF= 8 machine unit
and SF = 2100 unit.The experimentally observed values of the responsevariables for
differentvaluesof Wire Feed are given in Table 1.6 The scatter plots of pulse on time versus
response variables are shown in Figure 1.
Table 1.6 : Effect of wire feed on CR
Range (0-15)
Wire
Feed
Cutting
Rate
(mm/min)
7 2.15
7 2.15
8 2.15
8 2.15
9 2.15
Figure 1.9: Effect of Wire Feed on Cutting Rate
The cutting rate remains practically constant with the increase in wire feed These finding are in
line with a researcher [Hascalyk, A. and Caydas and U. (2004)]
In the sixth set of experiments: the wire tension is varied from 7 units to 9 units. The values of
the other control factors are given as Ton = 116 unit; Tofff = 31 ,Ip= 115 A: Sv =50V; Wf= 8
machine unit and Sf = 2100 unit.The experimentally observed values of the response variables for
different values of Wire Tension are given in Table 1.7 The scatter plots of Wire Tension versus
response variables are shown in Figure 1.11.
8. Mechanical Engineering: An International Journal ( MEIJ), Vol. 1, No. 1, May 2014
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Table 1.7: Effect of wire tension on CR
Range (0-15)
Wire
tension
Cutting
Rate
(mm/min)
7 2.15
7 2.15
8 2.15
8 2.15
9 2.15
Figure 1.10: Effect of Wire tension on Cutting Rate
4. Conclusion
From the above study is concluded that :
a) Cutting Rate is increase with the increase in pulse on time upto a certain amount of range beyond
this limit of pulse on time MRR start decrease.
b) CR is decreased with increase of pulse duration because discharge energy reduced which reduced
cutting rate.
c) CR is increased with increase of peak current because increase in discharge energy.
d) CR decreased with increase of servo gap voltage
e) The effect of Wire feed and Wire Tension is almost constant on CR.
f) Finaly the ranges of control factors on are selected
References :
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Wire EDM,” Machining Science and Technology, vol. 7, pp. 209–219, 2003 studied the variation of
work-piece surface roughness with varying pulse duration, open circuit
[2] M. T. Yan, P.H. Huang, “Accuracy improvement of wire-EDM by real-time wire tension control,”
Intl Journal of Machine Tools &Manufacture, vol. 44, pp. 807–814, 2004.
[3] S. F. Miller, C.C. Kao, A. J. Shih, J. Qu, “Investigation of wire electrical discharge machining of thin
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[7] H. Singh, R. Garg (2009), “Effects of process parameters on material removal rate in WEDM”,
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[11] http://www.sodick.jp/tech/img/discharge_fig02_new.gif.
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Authors’ Biographies:
Er. SonuDhiman passed his B.TechInMechanical Engg.fromHCTM Kaithal in 2011
and pursuing M.Tech in Industrial And Production Engg. at SKIET Kurukshetra. He
has one year of teaching experience. And it’s his first publication.