International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
A Review on Parametric Optimization in Wire Electric Discharge MachiningIJSRD
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters, include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Optimization of process parameters is necessary to reduce cost and time of manufacturing. Various optimization and relation finding methods are shown here which are frequently used by researchers. Few conclusions based on existing literature have been extracted from existing literature on optimization of WEDM process parameters.
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.
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 WIRE EDM PARAMETERS TO ACHIEVE A FINE SURFACE FINISHIjripublishers Ijri
Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal
energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses
an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of
thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire
is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During
the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and
the wire, eliminating the mechanical stresses during machining.
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
The document summarizes research on the micro-EDM process parameters for machining nickel-titanium shape memory alloys. It discusses how the micro-EDM process works based on electrical discharges that vaporize material in a small gap between the electrode and workpiece. The research investigated the effects of capacitance, discharge voltage, and electrode material on the material removal rate and tool wear rate during micro-EDM of nickel-titanium alloys. It found that material removal rate increased with higher capacitance and discharge voltage, and was better with a brass electrode than tungsten. Tool wear rate also increased with higher capacitance and voltage but was lower at lower energy levels and with a tungsten electrode.
This document provides a review of research on wire electric discharge machining (WEDM). It begins with an abstract that describes WEDM as a process that uses a continuously traveling wire electrode to produce complex shapes in electrically conductive materials by generating sparks between the wire and workpiece. The document then reviews research on WEDM, including studies optimizing process parameters to improve machining performance and productivity and reduce wire breakage. It also discusses the basic principles and cutting process of WEDM, noting that the exact sparking phenomena remains disputed, and lists common wire materials and their applications.
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.
A Review on Parametric Optimization in Wire Electric Discharge MachiningIJSRD
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters, include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Optimization of process parameters is necessary to reduce cost and time of manufacturing. Various optimization and relation finding methods are shown here which are frequently used by researchers. Few conclusions based on existing literature have been extracted from existing literature on optimization of WEDM process parameters.
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.
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 WIRE EDM PARAMETERS TO ACHIEVE A FINE SURFACE FINISHIjripublishers Ijri
Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal
energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses
an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of
thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire
is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During
the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and
the wire, eliminating the mechanical stresses during machining.
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
The document summarizes research on the micro-EDM process parameters for machining nickel-titanium shape memory alloys. It discusses how the micro-EDM process works based on electrical discharges that vaporize material in a small gap between the electrode and workpiece. The research investigated the effects of capacitance, discharge voltage, and electrode material on the material removal rate and tool wear rate during micro-EDM of nickel-titanium alloys. It found that material removal rate increased with higher capacitance and discharge voltage, and was better with a brass electrode than tungsten. Tool wear rate also increased with higher capacitance and voltage but was lower at lower energy levels and with a tungsten electrode.
This document provides a review of research on wire electric discharge machining (WEDM). It begins with an abstract that describes WEDM as a process that uses a continuously traveling wire electrode to produce complex shapes in electrically conductive materials by generating sparks between the wire and workpiece. The document then reviews research on WEDM, including studies optimizing process parameters to improve machining performance and productivity and reduce wire breakage. It also discusses the basic principles and cutting process of WEDM, noting that the exact sparking phenomena remains disputed, and lists common wire materials and their applications.
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.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
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.
Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Techniqueijtsrd
The cold work applications like aluminium extrusion, it allows complex shapes to be formed with very smooth surfaces and it is popular for visible architectural applications such as window frames, door frames, roofs, and sign frames should have high toughness, wear resistance, compressive strength, high corrosion resistance, high surface finish and complex profiles. AA 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. This material can satisfy the above requirements, because of its hardness and strength AA 6063 cannot be machined easily through traditional machining processes. Advanced machining processes are used only when there is no suitable traditional machining process to meet necessary requirements efficiently and economically. Among them wire cut EDM is employed because of its tight tolerances and high surface finish. Based on intense literature survey, it was noticed that very few works were reported on WEDM of AA 6063. As a part of our thesis, WEDM of AA 6063 is considered for the study. In this work Pulse on time, pulse off time, peak current, wire speed, wire tension and flushing pressure of dielectric medium are considered as parameters and their effect on performance measures, metal removal rate MRR and surface roughness will be studied through experimental investigation. Using Taguchi approach, considered parameters will be optimized for maximum MRR and minimum for Surface roughness separately. Taguchi method will be applied to generate mean S N ratios to identify the optimum process parameters. Kandukuri Srinivas | K. Anabayan | P. H. J. Venkatesh "Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31047.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31047/optimization-of-wire-cut-edm-of-aluminium-alloy-6063-by-using-taguchi-technique/kandukuri-srinivas
ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR...meijjournal
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.
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.
1) A novel technique called double electrodes synchronous servo electrical discharge grinding (DESSEDG) is presented to machine non-conductive engineering ceramics with high efficiency and precision by integrating advantages of electrical discharge machining (EDM) and mechanical grinding.
2) In the DESSEDG process, a conductive grinding wheel rotates on the workpiece surface while a thin copper sheet electrode is automatically fed to the area where the wheel and workpiece meet, causing electrical discharges that erode the workpiece surface.
3) The eroded layer is then removed by the grinding wheel, combining the material removal of EDM with mechanical grinding for higher efficiency machining of hard non-conductive ceramics compared
This document provides an overview of machining non-conducting materials using electrochemical discharge phenomena, known as spark assisted chemical engraving (SACE). SACE allows machining of materials like glass and ceramics. It involves applying a voltage between a tool electrode and counter electrode in an electrolyte solution, causing electrochemical discharges that erode the workpiece material. While studied since the 1960s, SACE has not been widely applied industrially. The document reviews the state of knowledge on SACE and discusses challenges that have limited its use, such as inconsistent machining results due to the complex interactions between process parameters.
Edm drilling of non conducting materials in deionised waterVaralakshmi Kothuru
The document discusses electrical discharge machining (EDM) of non-conductive materials like ceramics in deionized water. Typically, EDM requires a conductive layer on the workpiece, but this layer is difficult to regenerate in water. The study shows that a new conductive layer can be deposited on zirconium dioxide ceramic from the tool electrode during EDM in water. Process parameters are developed that balance material removal with regeneration of this assisting layer. Blind holes up to 1.5 mm deep are successfully drilled in ceramic, demonstrating the feasibility of the approach. Further improvements could enable industrial drilling of cooling holes in ceramic-coated turbine blades using this method.
This document provides a dissertation on investigating the machining characteristics of titanium alloy (Ti-6Al-4V) using the electrical discharge machining (EDM) process. The dissertation includes an introduction to traditional and non-traditional machining processes. It then focuses on EDM, including the history, types, principles, parameters, materials, advantages, and limitations. The methodology section describes the materials, equipment, experimental design using Taguchi methods, and parameters/levels studied. Results and discussions are presented on material removal rate, tool wear rate, surface roughness, and microhardness based on experiments. Finally, conclusions are drawn and scope for future work is discussed.
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- 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
Investigation on process response and parameters in wire electricaliaemedu
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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.
This document provides a review of research on electrical discharge machining (EDM) of non-conductive ceramic materials. It discusses how ceramics can be made electrically conductive through doping with conductive materials like titanium carbide. It then summarizes several studies that investigated EDM of doped ceramics and the effects of process parameters on material removal rate and surface finish. It also describes an "assisting electrode method" where a conductive layer forms on the ceramic surface during EDM, allowing discharges and machining to occur even for insulating materials. The document aims to demonstrate the feasibility of EDM for machining ceramics and potential applications of this innovative processing technique.
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
Optimization of electrical discharge machiningrakigeo01
This document summarizes a study that used the Taguchi method to optimize the electrical discharge machining (EDM) process for machining tungsten carbide composite. The researchers investigated how EDM process parameters affected material removal rate, electrode wear ratio, and microcrack density on the surface. They conducted experiments using an orthogonal array design from Taguchi methods. Analysis of variance was used to determine the most influential parameters and their optimal levels to maximize material removal rate while minimizing electrode wear ratio and microcrack density.
IRJET- Effect of Some Cutting Parameters on Metal Removal Rate, Surface Rough...IRJET Journal
The document discusses the effect of cutting parameters on metal removal rate, surface roughness, and overcut in the wire electric discharge machining (WEDM) process. It studies how parameters like pulse on-time, peak current, wire tension, wire feed rate, and water pressure impact these output measures. The study was conducted on EN-31 alloy steel using an ELECTRONICA SPRINTCUT WEDM machine. Mathematical models were developed using response surface methodology to correlate the relationships between input and output parameters. The models can help optimize the WEDM process for machining EN-31 steel.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
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.
Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Techniqueijtsrd
The cold work applications like aluminium extrusion, it allows complex shapes to be formed with very smooth surfaces and it is popular for visible architectural applications such as window frames, door frames, roofs, and sign frames should have high toughness, wear resistance, compressive strength, high corrosion resistance, high surface finish and complex profiles. AA 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. This material can satisfy the above requirements, because of its hardness and strength AA 6063 cannot be machined easily through traditional machining processes. Advanced machining processes are used only when there is no suitable traditional machining process to meet necessary requirements efficiently and economically. Among them wire cut EDM is employed because of its tight tolerances and high surface finish. Based on intense literature survey, it was noticed that very few works were reported on WEDM of AA 6063. As a part of our thesis, WEDM of AA 6063 is considered for the study. In this work Pulse on time, pulse off time, peak current, wire speed, wire tension and flushing pressure of dielectric medium are considered as parameters and their effect on performance measures, metal removal rate MRR and surface roughness will be studied through experimental investigation. Using Taguchi approach, considered parameters will be optimized for maximum MRR and minimum for Surface roughness separately. Taguchi method will be applied to generate mean S N ratios to identify the optimum process parameters. Kandukuri Srinivas | K. Anabayan | P. H. J. Venkatesh "Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31047.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31047/optimization-of-wire-cut-edm-of-aluminium-alloy-6063-by-using-taguchi-technique/kandukuri-srinivas
ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR...meijjournal
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.
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.
1) A novel technique called double electrodes synchronous servo electrical discharge grinding (DESSEDG) is presented to machine non-conductive engineering ceramics with high efficiency and precision by integrating advantages of electrical discharge machining (EDM) and mechanical grinding.
2) In the DESSEDG process, a conductive grinding wheel rotates on the workpiece surface while a thin copper sheet electrode is automatically fed to the area where the wheel and workpiece meet, causing electrical discharges that erode the workpiece surface.
3) The eroded layer is then removed by the grinding wheel, combining the material removal of EDM with mechanical grinding for higher efficiency machining of hard non-conductive ceramics compared
This document provides an overview of machining non-conducting materials using electrochemical discharge phenomena, known as spark assisted chemical engraving (SACE). SACE allows machining of materials like glass and ceramics. It involves applying a voltage between a tool electrode and counter electrode in an electrolyte solution, causing electrochemical discharges that erode the workpiece material. While studied since the 1960s, SACE has not been widely applied industrially. The document reviews the state of knowledge on SACE and discusses challenges that have limited its use, such as inconsistent machining results due to the complex interactions between process parameters.
Edm drilling of non conducting materials in deionised waterVaralakshmi Kothuru
The document discusses electrical discharge machining (EDM) of non-conductive materials like ceramics in deionized water. Typically, EDM requires a conductive layer on the workpiece, but this layer is difficult to regenerate in water. The study shows that a new conductive layer can be deposited on zirconium dioxide ceramic from the tool electrode during EDM in water. Process parameters are developed that balance material removal with regeneration of this assisting layer. Blind holes up to 1.5 mm deep are successfully drilled in ceramic, demonstrating the feasibility of the approach. Further improvements could enable industrial drilling of cooling holes in ceramic-coated turbine blades using this method.
This document provides a dissertation on investigating the machining characteristics of titanium alloy (Ti-6Al-4V) using the electrical discharge machining (EDM) process. The dissertation includes an introduction to traditional and non-traditional machining processes. It then focuses on EDM, including the history, types, principles, parameters, materials, advantages, and limitations. The methodology section describes the materials, equipment, experimental design using Taguchi methods, and parameters/levels studied. Results and discussions are presented on material removal rate, tool wear rate, surface roughness, and microhardness based on experiments. Finally, conclusions are drawn and scope for future work is discussed.
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- 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
Investigation on process response and parameters in wire electricaliaemedu
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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.
This document provides a review of research on electrical discharge machining (EDM) of non-conductive ceramic materials. It discusses how ceramics can be made electrically conductive through doping with conductive materials like titanium carbide. It then summarizes several studies that investigated EDM of doped ceramics and the effects of process parameters on material removal rate and surface finish. It also describes an "assisting electrode method" where a conductive layer forms on the ceramic surface during EDM, allowing discharges and machining to occur even for insulating materials. The document aims to demonstrate the feasibility of EDM for machining ceramics and potential applications of this innovative processing technique.
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
Optimization of electrical discharge machiningrakigeo01
This document summarizes a study that used the Taguchi method to optimize the electrical discharge machining (EDM) process for machining tungsten carbide composite. The researchers investigated how EDM process parameters affected material removal rate, electrode wear ratio, and microcrack density on the surface. They conducted experiments using an orthogonal array design from Taguchi methods. Analysis of variance was used to determine the most influential parameters and their optimal levels to maximize material removal rate while minimizing electrode wear ratio and microcrack density.
IRJET- Effect of Some Cutting Parameters on Metal Removal Rate, Surface Rough...IRJET Journal
The document discusses the effect of cutting parameters on metal removal rate, surface roughness, and overcut in the wire electric discharge machining (WEDM) process. It studies how parameters like pulse on-time, peak current, wire tension, wire feed rate, and water pressure impact these output measures. The study was conducted on EN-31 alloy steel using an ELECTRONICA SPRINTCUT WEDM machine. Mathematical models were developed using response surface methodology to correlate the relationships between input and output parameters. The models can help optimize the WEDM process for machining EN-31 steel.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
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
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The document discusses residual stresses that arise during welding due to localized heating and rapid cooling. It analyzes how welding conditions like travel speed, specimen size, constraints, and preheating can affect residual stress distributions. A finite element model is used to simulate butt welding and predict residual stresses in the weld and base metal. The results show that transverse and longitudinal residual stresses are highest near the weld and decrease with increasing distance. Faster travel speeds, larger specimen sizes, and preheating can reduce residual stresses, while external constraints decrease transverse shrinkage and associated stresses.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document presents a study on developing equations to estimate energy requirements for processing the local alcoholic beverage "Burukutu" in Nigeria. The researchers conducted studies at 18 production sites across 6 local government areas in Benue State, Nigeria. Mathematical expressions were developed to evaluate the energy needed for each of the 7 unit operations in Burukutu production. These equations were then used to calculate the total energy expenditure at each site based on input data. Regression analysis found no significant difference in energy requirements between the 18 sites. The developed equations relate energy requirements to the amount of red sorghum input and can estimate energy needs for each unit operation and the total production process.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes and compares different recommendation generation algorithms. It focuses on collaborative filtering using Pearson's correlation coefficient. Pearson's coefficient is a type of memory-based collaborative filtering that provides accurate recommendations by calculating similarity between users based on their item ratings. It allows scaling to large datasets and outperforms other methods by providing higher quality recommendations while being simple to implement. The document also briefly introduces other common recommendation techniques like content-based and model-based collaborative filtering.
Este documento presenta una lista de productos de aislamiento térmico y acústico como fibras de vidrio, poliéster, espumas de polietileno, láminas de icopor liso y rústico, láminas de policarbonato alveolar y accesorios. Incluye detalles como diámetro, espesor, largo, color, proveedor y precio de cada producto.
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 on Parametric Optimization in Wire Electric Discharge MachiningIJSRD
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters, include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Optimization of process parameters is necessary to reduce cost and time of manufacturing. Various optimization and relation finding methods are shown here which are frequently used by researchers. Few conclusions based on existing literature have been extracted from existing literature on optimization of WEDM process parameters.
This document provides an overview of wire electrical discharge grinding (WEDG). WEDG is a micro machining process that uses electrical discharges between a rotating workpiece and a traveling wire electrode to remove material without mechanical contact. Key parameters that affect the WEDG process include voltage, capacitance, spindle speed, and feed rate, which determine the discharge energy and ultimately the material removal rate, surface finish, and machining time. The WEDG process provides advantages such as high precision tolerances and the ability to machine complex and delicate parts without mechanical forces or burrs.
IRJET- Investigation of Wire EDM Process Parameters for Machining of Mild...IRJET Journal
This document discusses an investigation of wire electrical discharge machining (WEDM) process parameters for machining mild steel specimens using Taguchi methods. The parameters investigated are pulse-on time, pulse-off time, peak current, and servo voltage. The responses measured are cutting rate, surface roughness, dimensional deviation, and wire wear ratio. Experiments will be conducted on a WEDM machine to determine the optimal process parameters that maximize cutting rate while minimizing surface roughness, dimensional deviation, and wire wear.
Investigation on process response and parameters in wire electricalIAEME Publication
This document summarizes a study that investigated the effects of process parameters on wire electrical discharge machining (WEDM) of Inconel 625. The study used Taguchi's design of experiments methodology to determine the optimal levels of six machining parameters (pulse-on time, pulse-off time, wire feed, upper flush, lower flush, wire tension) for minimizing kerf width, electrode wire wear, and maximizing surface hardness. Twenty-five experiments were conducted according to an L25 orthogonal array. Regression analysis was used to establish relationships between the process parameters and responses. The results showed good agreement between experimental and predicted values, demonstrating the methodology can determine optimal machining conditions for WEDM of Inconel
This document discusses analyzing process parameters in wire electrical discharge machining (WEDM) of Inconel 718, a nickel-based super alloy. The objectives are to investigate significant WEDM parameters that affect material removal rate, electrode wear ratio, and hardness; study the effect of parameters on dimensional output like circularity and cylindricity; establish optimal WEDM parameters for Inconel; and develop an empirical model using Taguchi's design of experiments. The document reviews literature on modeling and optimizing WEDM performance and discusses the mechanism and influencing parameters of the WEDM process.
Investigation on process response and parameters in wire electrical discharge...IAEME Publication
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
MODELING AND ANALYSIS OF SURFACE ROUGHNESS AND WHITE LATER THICKNESS IN WIRE-...IAEME Publication
White layer thickness (WLT) formed and surface roughness in wire electric discharge turning (WEDT) of tungsten carbide composite has been made to model through response surface methodology (RSM). A Taguchi’s standard Design of experiments involving five input variables with three levels has been employed to establish a mathematical model between input parameters and responses. Percentage of cobalt content, spindle speed, Pulse on-time, wire feed and pulse off-time were changed during the experimental tests based on the Taguchi’s orthogonal array L27 (3^13). Analysis of variance (ANOVA) revealed that the mathematical models obtained can adequately describe performance within the parameters of the factors considered. There was a good agreement between the experimental and predicted values in this study.
A Literature Review On Dry Wire Electrical Discharge MachiningIJSRD
This document provides a literature review on dry wire electrical discharge machining (EDM). It summarizes several past studies that investigated dry EDM using various gases as dielectrics and how it improves performance over conventional EDM using liquid dielectrics. The review examines factors like material removal rate, surface finish, tool wear rate, and process parameters that influence these outputs. It discusses the basic working principles of dry wire EDM and evaluates the findings of multiple past studies on the effects of different machining variables in dry EDM.
Dynamic Monitoring Of Information in Large Scale Power GridsIJSRD
this document proposes the software model for detection and analysis of cascading faults in the operation of large scale power grids. Using data mining technologies, probable patterns can be detected for faults and proper mitigation measures can be taken. Firstly, the fault is detected by checking the stability of system. Then event sequences are calculated to best approximate the fault node. Then by analyzing the severity of vulnerability and region in which vulnerability would occur, proper ICT Technologies can make operators aware about the faults. Hence, speeding up the existing mechanisms. This model aims to solve problem of detection more efficiently than existing systems.
STUDY OF PROCESS PARAMETER OF WIRE ELECTRIC DISCHARGE MACHINING: THE REVIEWIAEME Publication
Wire EDM is a variation of the Electric Discharge Machining and is commonly known as wire-cut EDM. In WEDM, material is eroded from the work material by a series of discrete sparks
occurring between the work piece and the wire which is generally act as electrode, separated by a stream of dielectric fluid. Dielectric fluid commonly used is deionized water which is act as coolant and flushes the debris away. Work piece is generally electric conductive.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
Experimental Investigation to Determine Influence of Process Parameters on Su...IRJET Journal
This document summarizes an experimental investigation into determining the influence of process parameters on surface quality in wire cut electrical discharge machining (WEDM). The study examines the relationship between input process parameters like pulse-on time, pulse-off time, peak current, wire material, and workpiece material, and output variables like surface roughness and electrode wear. Experiments were conducted using an aluminum workpiece material and brass wire electrode. Based on the chosen input parameters and performance measures, a L9 orthogonal array was used to optimize the process parameters for machining aluminum alloys by WEDM.
1. Wire electrical discharge machining (WEDM) is a non-conventional thermo-electric process that removes material from a workpiece using a series of electrical sparks between a wire electrode and the workpiece submerged in dielectric fluid.
2. Many factors influence the WEDM process, including wire positioning, flushing pressure, and material properties. Mathematical models are used to understand relationships between process parameters like peak current and duty factor, and performance measures like material removal rate.
3. Experiments are conducted to determine the effects of process parameters like pulse on/off time and servo voltage on material removal rate and surface roughness when machining H13 hot die steel. The optimal settings are identified using statistical techniques
REVIEW ON EFFECTS OF PROCESS PARAMETERS IN WIRE CUT EDMIRJET Journal
This document reviews literature on the effects of process parameters in wire cut electrical discharge machining (WEDM). It begins by providing background on WEDM and describing some common process parameters like pulse on time, pulse off time, peak current, and servo feed. It then summarizes several research papers that studied the effects of adjusting various WEDM parameters on outcomes like material removal rate, surface roughness, and dimensional accuracy when machining different materials like nickel alloys, titanium alloys, and tool steels. Overall, the literature review shows that the pulse on time generally has the greatest influence on material removal rate, while adjustments to pulse off time and peak current can also significantly impact machining performance and surface finish.
Study of process parameter of wire electric discharge machining the reviewIAEME Publication
This document summarizes the process parameters of wire electric discharge machining (WEDM). It discusses the key electrical parameters like pulse duration, pulse interval, servo voltage, and peak current. It also discusses the electrode wire parameters like wire size, material, tension and feed. Additionally, it covers dielectric fluid parameters and workpiece parameters that influence the WEDM process. The document provides details on how each parameter impacts material removal rate and machining characteristics.
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
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electric discharge machining of stainless steelMustufa Abidi
This document provides an overview of electric discharge machining (EDM) and its application to machining stainless steels. It discusses the principles and parameters of EDM, including electrical parameters like voltage, current, and pulse duration/interval. It reviews research on using EDM variants like wire EDM and micro-EDM to machine different stainless steel grades. The document examines models used to determine optimal EDM conditions and discusses trends and gaps in the research.
Effect of Electrode Materials and Optimization of Electric Discharge Machinin...IRJET Journal
This document discusses an experimental investigation into optimizing electric discharge machining (EDM) of M2 tool steel. EDM is used to machine hard materials like tool steels. The study examined the effect of pulse current on material removal rate, electrode wear rate, and surface roughness when machining M2 steel with copper and tungsten copper electrodes. Optimization of output parameters like material removal rate and surface roughness was also done using Grey-Taguchi analysis. The results showed that tungsten copper achieved higher material removal rates and depths than copper. Using Taguchi, the best surface roughness was achieved at lower current, while higher material removal occurred at higher current. Grey analysis found the optimal parameters were higher current, medium pulse on
IRJET- Advance Manufacturing Processes Review Part IV: Electrical Dischar...IRJET Journal
1) Electrical discharge machining (EDM) is a non-traditional machining process that uses electric sparks to erode conductive materials.
2) EDM can machine hard materials like steel and super alloys regardless of their hardness by melting and vaporizing small amounts of material with each electric spark.
3) The document reviews research on EDM process parameters and their effects on material removal rate, surface roughness, and tool wear. It also summarizes recent research trends in EDM like ultrasonic vibration-assisted EDM and EDM in water.
A tale of scale & speed: How the US Navy is enabling software delivery from l...sonjaschweigert1
Rapid and secure feature delivery is a goal across every application team and every branch of the DoD. The Navy’s DevSecOps platform, Party Barge, has achieved:
- Reduction in onboarding time from 5 weeks to 1 day
- Improved developer experience and productivity through actionable findings and reduction of false positives
- Maintenance of superior security standards and inherent policy enforcement with Authorization to Operate (ATO)
Development teams can ship efficiently and ensure applications are cyber ready for Navy Authorizing Officials (AOs). In this webinar, Sigma Defense and Anchore will give attendees a look behind the scenes and demo secure pipeline automation and security artifacts that speed up application ATO and time to production.
We will cover:
- How to remove silos in DevSecOps
- How to build efficient development pipeline roles and component templates
- How to deliver security artifacts that matter for ATO’s (SBOMs, vulnerability reports, and policy evidence)
- How to streamline operations with automated policy checks on container images
Unlocking Productivity: Leveraging the Potential of Copilot in Microsoft 365, a presentation by Christoforos Vlachos, Senior Solutions Manager – Modern Workplace, Uni Systems
Maruthi Prithivirajan, Head of ASEAN & IN Solution Architecture, Neo4j
Get an inside look at the latest Neo4j innovations that enable relationship-driven intelligence at scale. Learn more about the newest cloud integrations and product enhancements that make Neo4j an essential choice for developers building apps with interconnected data and generative AI.
Building RAG with self-deployed Milvus vector database and Snowpark Container...Zilliz
This talk will give hands-on advice on building RAG applications with an open-source Milvus database deployed as a docker container. We will also introduce the integration of Milvus with Snowpark Container Services.
Alt. GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using ...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Goodbye Windows 11: Make Way for Nitrux Linux 3.5.0!SOFTTECHHUB
As the digital landscape continually evolves, operating systems play a critical role in shaping user experiences and productivity. The launch of Nitrux Linux 3.5.0 marks a significant milestone, offering a robust alternative to traditional systems such as Windows 11. This article delves into the essence of Nitrux Linux 3.5.0, exploring its unique features, advantages, and how it stands as a compelling choice for both casual users and tech enthusiasts.
Essentials of Automations: The Art of Triggers and Actions in FMESafe Software
In this second installment of our Essentials of Automations webinar series, we’ll explore the landscape of triggers and actions, guiding you through the nuances of authoring and adapting workspaces for seamless automations. Gain an understanding of the full spectrum of triggers and actions available in FME, empowering you to enhance your workspaces for efficient automation.
We’ll kick things off by showcasing the most commonly used event-based triggers, introducing you to various automation workflows like manual triggers, schedules, directory watchers, and more. Plus, see how these elements play out in real scenarios.
Whether you’re tweaking your current setup or building from the ground up, this session will arm you with the tools and insights needed to transform your FME usage into a powerhouse of productivity. Join us to discover effective strategies that simplify complex processes, enhancing your productivity and transforming your data management practices with FME. Let’s turn complexity into clarity and make your workspaces work wonders!
Enchancing adoption of Open Source Libraries. A case study on Albumentations.AIVladimir Iglovikov, Ph.D.
Presented by Vladimir Iglovikov:
- https://www.linkedin.com/in/iglovikov/
- https://x.com/viglovikov
- https://www.instagram.com/ternaus/
This presentation delves into the journey of Albumentations.ai, a highly successful open-source library for data augmentation.
Created out of a necessity for superior performance in Kaggle competitions, Albumentations has grown to become a widely used tool among data scientists and machine learning practitioners.
This case study covers various aspects, including:
People: The contributors and community that have supported Albumentations.
Metrics: The success indicators such as downloads, daily active users, GitHub stars, and financial contributions.
Challenges: The hurdles in monetizing open-source projects and measuring user engagement.
Development Practices: Best practices for creating, maintaining, and scaling open-source libraries, including code hygiene, CI/CD, and fast iteration.
Community Building: Strategies for making adoption easy, iterating quickly, and fostering a vibrant, engaged community.
Marketing: Both online and offline marketing tactics, focusing on real, impactful interactions and collaborations.
Mental Health: Maintaining balance and not feeling pressured by user demands.
Key insights include the importance of automation, making the adoption process seamless, and leveraging offline interactions for marketing. The presentation also emphasizes the need for continuous small improvements and building a friendly, inclusive community that contributes to the project's growth.
Vladimir Iglovikov brings his extensive experience as a Kaggle Grandmaster, ex-Staff ML Engineer at Lyft, sharing valuable lessons and practical advice for anyone looking to enhance the adoption of their open-source projects.
Explore more about Albumentations and join the community at:
GitHub: https://github.com/albumentations-team/albumentations
Website: https://albumentations.ai/
LinkedIn: https://www.linkedin.com/company/100504475
Twitter: https://x.com/albumentations
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
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1. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
805 | P a g e
A Review of recent work in wire electrical discharge machining
(WEDM)
Prof. Vijay D.Patel*, Dr. Rajeev V. Vaghmare**
*(Assistsant Professor in Mechatronics at U.V.Patel collage of engginering ,Mehsana, Gujarat)
**(Principal,SABAR institute of technology for GIRLS, Majra,Gujarat)
Abstract
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.
This paper reviews the vast array of
research work carried out from the EDM
process to the development of the WEDM. It
reports on the WEDM research involving the
optimization of the process parameters
surveying the influence of the various factors
affecting the machining performance and
productivity. The paper also highlights the
adaptive monitoring and control of the process
investigating the feasibility of the different
control strategies of obtaining the optimal
machining conditions. A wide range of WEDM
industrial applications are reported together
with the development of the hybrid machining
processes. The final part of the paper discusses
these developments and outlines the possible
trends for future WEDM research.
Keywords: Wire electrical discharge machining
(WEDM);Process optimization; Cutting rate;
Material removal rate; Surface finish Electric
discharge machining (EDM), Metal removal rate
(MRR), Surface roughness (SR)
I. INTRODUCTION
Wire electrical discharge machining
(WEDM) is a widely accepted non-traditional
material removal process used to manufacture
components with intricate shapes and profiles. It is
considered as a unique adaptation of the
conventional EDM process, which uses an electrode
to initialize the sparking process. However, WEDM
utilizes a continuously travelling wire electrode
made of thin copper, brass or tungsten of diameter
0.05–0.3 mm, which is capable of achieving very
small Corner radii. The wire is kept in tension using
a mechanical tensioning device reducing the
tendency of producing inaccurate parts. During the
WEDM process, the material is eroded ahead of the
wire and there is no direct contact between the work
piece and the wire, eliminating the mechanical
stresses during machining. In addition, the WEDM
process is able to machine exotic and high strength
and temperature resistive (HSTR) materials and
eliminate the geometrical changes occurring in the
machining of heat-treated steels.
WEDM was first introduced to the
manufacturing industry in the late 1960s. The
development of the process was the result of seeking
a technique to replace the machined electrode used
in EDM. In 1974, D.H. Dule-bohn applied the
optical-line follower system to automatically control
the shape of the component to be machined by the
WEDM process [1]. By 1975, its popularity was
rapidly increasing, as the process and its capabilities
were better understood by the industry [2]. It was
only towards the end of the 1970s, when computer
numerical control (CNC) system was initiated into
WEDM that brought about a major evolution of the
machining process. As a result, the broad
capabilities of the WEDM process were extensively
exploited for any through-hole machining owing to
the wire, which has to pass through the part to be
machined. The common applications of WEDM
include the fabrication of the stamping and extrusion
tools and dies, fixtures and gauges, prototypes,
aircraft and medical parts, and grinding wheel form
tools.
This paper provides a review on the various
academic research areas involving the WEDM
process, and is the sister paper to a review by Ho
and Newman [3] on die-sinking EDM. It first
presents the process overview based on the widely
accepted principle of thermal conduction and
highlights some of its applications. The main section
of the paper focuses on the major WEDM research
activities, which include the WEDM process
optimization together with the WEDM process
monitoring and control. The final part of the paper
discusses these topics and suggests the future
WEDM research direction.
2. WEDM
This section provides the basic principle of
the WEDM process and the variations of the process
2. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
806 | P a g e
combining other material removal techniques.
2.1. Process
The material removal mechanism of
WEDM is very similar to the conventional EDM
process involving the erosion effect produced by the
electrical discharges (sparks). In WEDM, material
is eroded from the work-piece by a series of discrete
sparks occurring between the work piece and the
wire separated by a stream of dielectric fluid, which
is continuously fed to the machining zone [4].
However, today’s WEDM process is commonly
conducted on work pieces that are totally
submerged in a tank filled with dielectric fluid.
Such a submerged method of WEDM promotes
temperature stabilization and efficient flushing
especially in cases where the work piece has
varying thickness. The WEDM process makes use
of electrical energy generating a channel of plasma
between the cathode and anode [5], and turns it into
thermal energy [6] at a temperature in the range of
8000–12,000 v
C [7] or as high as 20,000 v
C [8]
initializing a substantial amount of heating and
melting of material on the surface of each pole.
When the pulsating direct current power supply
occurring between 20,000 and 30,000 Hz [9] is
turned off, the plasma channel breaks down. This
causes a sudden reduction in the temperature
allowing the circulating dielectric fluid to implore
the plasma channel and flush the molten particles
from the pole surfaces in the form of microscopic
debris.
While the material removal mechanisms of
EDM and WEDM are similar, their functional
characteristics are not identical. WEDM uses a thin
wire continuously feeding through the work piece
by a microprocessor, which enable parts of complex
shapes to be machined with exceptional high
accuracy. A varying degree of taper ranging from
15v
for a 100 mm thick to 30v
for a 400 mm thick
workpiece can also be obtained on the cut surface.
The microprocessor also constantly main-tains the
gap between the wire and the work piece, which
varies from 0.025 to 0.05 mm [2]. WEDM
eliminates the need for elaborate pre-shaped
electrodes, which are commonly required in EDM
to perform the roughing and finishing operations. In
the case of WEDM, the wire has to make several
machining passes along the profile to be machined
to attain the required dimensional accuracy and
surface finish (SR) quality. Kunieda and Furudate
[10] tested the feasibility of con-ducting dry
WEDM to improve the accuracy of the fin-ishing
operations, which was conducted in a gas
atmosphere without using dielectric fluid. The
typical WEDM cutting rates (CRs) are 300
mm2
/min for a 50 mm thick D2 tool steel and 750
mm2
/min for a 150 mm thick aluminium [11], and
SR quality is as fine as 0.04–0.25 lRa. In addition,
WEDM uses deionised water instead of hydrocarbon
oil as the dielectric fluid and contains it within the
sparking zone. The deionised water is not suitable
for conventional EDM as it causes rapid electrode
wear, but its low viscosity and rapid cooling rate
make it ideal for WEDM [12].
3. Main areas of research
The authors have organized the various
WEDM research into two major areas namely
WEDM process optimization together with WEDM
process monitoring and control.
3.1. Process Optimization
Today, the most effective machining
strategy is determined by identifying the different
factors affecting the WEDM process and seeking the
different ways of obtaining the optimal machining
condition and performance. This section provides a
study on the numerous machining strategies
involving the design of the process parameter and
the modeling of the process.
3.1.1. Process parameters design
The settings for the various process
parameters required in the WEDM process play a
crucial role in producing an optimal machining
performance. This section shows some of the
analytical and statistical methods used to study the
effects of the parameters on the typical WEDM
performance measures such as CR, MRR and SR.
3.1.1.1Factors affecting the performance
measures.
WEDM is a complex machining process
controlled by a large number of process parameters
such as the pulse duration, discharge frequency and
discharge current intensity. Any slight variations in
the process parameters can affect the machining
performance measures such as surface roughness
and CR, which are two of the most significant
aspects of the WEDM operation [44]. Suziki and
Kishi [45] studied the reduction of discharge energy
to yield a better surface roughness, while Luo [46]
discovered the additional need for a high-energy
efficiency to maintain a high machining rate without
damaging the wire. Several authors [47] have also
studied the evolution of the wire tool performance
affecting the machining accuracy, costs and
performance measures.
The selection of appropriate machining
conditions for the WEDM process is based on the
analysis relating the various process parameters to
different performance measures namely the CR,
MRR and SR. Traditionally; this was carried out by
relying heavily on the operator’s experience or
conservative technological data provided by the
WEDM equipment manufacturers, which produced
inconsistent machining performance. Levy and
Maggi [48] demonstrated that the parameter settings
3. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
807 | P a g e
given by the manufacturers are only applicable for
the common steel grades. The settings for
machining new materials such as advanced
ceramics and MMCs have to be further optimized
experimentally.
3.1.1.2. Effects of the process parameters on the
cutting rate. Many different types of problem-
solving quality tools have been used to investigate
the significant factors and its inter-relationships
with the other variables in obtaining an optimal
WEDM CR. Konda et al. [49] classified the various
potential factors affecting the WEDM performance
measures into five major categories namely the
different properties of the work piece material and
dielectric fluid, machine characteristics, adjustable
machining parameters, and component geometry. In
addition, they applied the design of experiments
(DOE) technique to study and optimize the possible
effects of variables during process design and
development, and validated the experimental results
using noise-to-signal (S/N) ratio analysis. Tarng et
al. [50] employed a neural network system with the
application of a simulated annealing algorithm for
solving the multi-response optimization problem. It
was found that the machining parameters such as
the pulse on/off duration, peak current, open circuit
volt-age, servo reference voltage, electrical
capacitance and table speed are the critical
parameters for the estimation of the CR and SR.
Huang et al. [51] argued that several published
works [50,52,53] are concerned mostly with the
optimization of parameters for the roughing cutting
operations and proposed a practical strategy of
process planning from roughing to finishing
operations. The experimental results showed that
the pulse on-time and the distance between the wire
periphery and the work piece surface affect the CR
and SR significantly. The effects of the discharge
energy on the CR and SR of a MMC have also been
investigated [54].
3.1.2. Process modeling
In addition, the modeling of the WEDM
process by means of mathematical techniques has
also been applied to effectively relate the large
number of process variables to the different
performance of the process. Speeding and Wang
[62] developed the modeling techniques using the
response surface methodology and artificial neural
network technology to predict the process
performance such as CR, SR and surface waviness
within a reasonable large range of input factor
levels. Liu and Esterling [63] proposed a solid
modeling method, which can precisely represent the
geometry cut by the WEDM process, whereas Hsue
et al. [64] developed a model to estimate the MRR
during geo-metrical cutting by considering wire
deflection with transformed exponential trajectory
of the wire centre. Spur and Scho¨nbeck [65]
designed a theoretical model studying the influence
of the workpiece material and the pulse-type
properties on the WEDM of a work-piece with an
anodic polarity. Han et al. [66] developed a
simulation system, which accurately reproduces the
discharge phenomena of WEDM. The system also
applies an adaptive control, which automatically
generates an optimal machining condition for high
precision WEDM.
3.2. Process monitoring and control
The application of the adaptive control
systems to the WEDM is vital for the monitoring
and control of the process. This section investigates
the advanced monitoring and control systems
including the fuzzy, the wire breakage and the self-
tuning adaptive control systems used in the WEDM
process.
3.2.1. Fuzzy control system
The proportional controllers have
traditionally been used in the servo feed control
system to monitor and evaluate the gap condition
during the WEDM process. However, the
performance of the controllers was limited by the
machining conditions, which considerably vary with
the parameters settings. Kinoshita et al. [67]
investigated the effects of wire feed rate, wire
winding speed, wire tension and electrical
parameters on the gap conditions during WEDM. As
a result, many conventional control algorithms based
on explicit mathematical and statistical models have
been developed for EDM or WEDM operations [68–
72]. Several authors [73,74] have also developed a
pulse discrimination sys-tem providing a means of
analyzing and monitoring the pulse trains under the
various WEDM conditions quantitatively. Although
these types of control systems can be applied to a
wide range of machining conditions, it cannot
respond to the gap condition when there is an
unexpected disturbance [75].
In recent years, the fuzzy control system has been
applied to WEDM process to achieve optimum and
highly efficient machining. Several authors claimed
that the fuzzy logic control system implements a
control strategy, which captures the expert’s
knowledge or operator’s experience in maintaining
the desired machining operation [76]. In addition,
the fuzzy logic controller does not require any
comprehensive mathematical models adapting to the
dynamic behavior of the WEDM operation [77].
Several authors [75,78] proposed the sparking
frequency monitoring and adaptive control systems
based on the fuzzy logic control and the adjusting
strategies, which can be applied to a wide range of
machining conditions. Liao and Woo [79] also
designed a fuzzy controller with an online pulse
monitoring system isolating the discharging noise
and discriminating the ignition delay time of each
4. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
808 | P a g e
pulse. EDM pulses can be classified into open,
spark, arc, off or short, which are dependent on the
ignition delay time, and have a direct influence on
the MRR, SR, electrode wear and accuracy of the
part [80,81].
3.2.2. Wire inaccuracy adaptive control systems
The occurrence of wire breakage during
WEDM is one of the most undesirable machining
characteristics greatly affecting the machining
accuracy and performance together with the quality
of the part produced. Many attempts have made to
develop an adaptive control system providing an
online identification of any abnormal machining
condition and a control strategy preventing the wire
from breaking without compromising the various
WEDM performance measures. This section reports
research from a collection of published work
involving the adaptive control of wire breakage,
wire lag and wire vibration.
3.2.2.1. Wire breakage. A wide variety of the
control strategies preventing the wire from breaking
are built on the knowledge of the characteristics of
wire break-age. Kinoshita et al. [82] observed the
rapid rise in pulse frequency of the gap voltage,
which continues for about 5–40 ms before the wire
breaks. They developed a monitoring and control
system that switches off the pulse generator and
servo system preventing the wire from breaking but
it affects the machining efficiency. Several authors
[83,84] also suggested that the concentration of
electrical discharges at a certain point of the wire,
which causes an increase in the localized
temperature resulting in the breakage of the wire.
However, the adaptive control system concentrating
on the detection of the sparking location and the
reduction of the discharge energy was developed
without making any considerations to the MRR.
The breakage of the wire has also been linked to the
rise in the number of short-circuit pulses lasting for
more than 30 ms until the wire broke [85].
Other authors [86] argued that the wire breakage is
correlated to the sudden increase in sparking
frequency. It was also found that their proposed
monitoring and control system based on the online
analysis of the sparking frequency and the real-time
regulation of the pulse off-time affects the MRR.
Liao et al. [87] remedied the problem by relating the
MRR to the machining parameters and using a new
computer-aided pulse discrimination system based
on the pulse train analysis to improve the machining
speed. Whereas Yan and Liao [88,89] applied a
self-learning fuzzy control strategy not only to
control the sparking frequency but also to maintain
a high MRR by adjusting in real time the off time
pulse under a constant feed-rate machining
condition.
The breaking of the wire is also due to the
excessive thermal load producing unwarranted heat
on the wire electrode. Most of the thermal energy
generated during the WEDM process is transferred
to the wire while the rest is lost to the flushing fluid
or radiation [86]. How-ever, when the instantaneous
energy rate exceeds a certain limit depending on the
thermal properties of the wire material, the wire will
break. Several authors [90–92] investigated the
influence of the various machining parameters on
the thermal load of the wire and developed a thermal
model simulating the WEDM process. In addition to
the sparking characteristics or the temperature
distribution, the mechanical strength of the wire also
has a significant effect on the occurrence of the wire
breakage. Luo [93] claimed that the wire material
yielding and fracture contribute to the wire
breakage, whilst an increase in temperature
aggravates the failure process.
3.2.2.2. Wire lag and wire vibration. The main
factors contributing to the geometrical inaccuracy of
the WEDMed part are the various process forces
acting on the wire causing it to depart for the
programmed path. These forces include the
mechanical forces produced by the pressure from the
gas bubbles formed by the plasma of the erosion
mechanism, axial forces applied to straighten the
wire, the hydraulic forces induced by the flushing,
the electro-static forces acting on the wire and the
electro-dynamic forces inherent to the spark
generation [94,95].
As a result, the static deflection in the form
of a lag effect of the wire is critically studied in
order to pro-duce an accurate cutting tool path.
Several authors [93,96,97] performed a parametric
study on the geo-metrical inaccuracy of the part
caused by the wire lag and attempted to model
WEDM process mathematically. Whereas Beltrami
and Dauw [98] monitored and controlled the wire
position online by means of an optical sensor with a
control algorithm enabling virtually any contour to
be cut at a relatively high cutting speed. A number
of geometric tool motion compensation methods,
which increase the machining gap and prevent
gauging or wire breakages when cutting areas with
high curvatures such as corners with small radii have
also been developed [99,100]. Lin et al. [101]
developed a control strategy based on the fuzzy
logic to improve the machining accuracy and
concentrated sparking at corner parts without
affecting the cutting feed rates.
In addition, the dynamic behavior of the
wire during WEDM is also restrained to avoid
cutting inaccuracies. There are a few discussions on
the design and development of a monitoring and
control system for compensating the behavior of the
wire vibration [86,102]. Dauw et al. [103] also
5. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
809 | P a g e
reported that the vibration of the wire can be
substantially reduced when the wire and the wire
guides are completely submerged in the working
tank filled with deionised water. Several authors
[104] derived a mathematical model analysing the
transient response of the wire vibration based on the
force acting on the tool wire in a single discharge
process. A number of authors [105,106] reviewed
the research and development of the various
advanced monitoring and control systems used in
EDM and WEDM processes.
In addition, the dynamic behavior of the
wire during WEDM is also restrained to avoid
cutting inaccuracies. There are a few discussions on
the design and development of a monitoring and
control system for compensating the behavior of the
wire vibration [86,102]. Dauw et al. [103] also
reported that the vibration of the wire can be
substantially reduced when the wire and the wire
guides are completely submerged in the working
tank filled with deionised water. Several authors
[104] derived a mathematical model analysing the
transient response of the wire vibration based on the
force acting on the tool wire in a single discharge
process. A number of authors [105,106] reviewed
the research and development of the various
advanced monitoring and control systems used in
EDM and WEDM processes.
3.2.3. Self-tuning adaptive control systems
In recent years, the WEDM research and
development has explored control strategies
adjusting to the variation in the power density
required in machining a workpiece with varying
thickness. Several authors [82,85] found out that a
change in the workpiece thickness during
machining leads to an increase in the wire thermal
density and an eventual breaking of the wire.
Rajurkar et al. [107,108] proposed an adaptive
control system with a multiple input model that
monitors and controls the sparking frequency
according to the online identified workpiece height.
Other authors [72] developed a system that involves
an explicit mathematical model requiring a number
of experiments and statistical techniques. Yan et al.
[109] used the neural networks to estimate the
workpiece height and the fuzzy control logic to
suppress the wire breakage when a workpiece with
variable height is machined.
The application of a knowledge-based
control system to control the adverse WEDM
conditions has also been experimented. Snoeys et
al. [110] proposed a knowledge-based system,
which comprises of three modules, namely work
preparation, process control and operator assistance
or fault diagnosis, enabling the monitoring and
control of the WEDM process. The work
preparation module determines the optimal
machining parameter settings, while the operator
assistance and fault diagnostics databases advise the
operators and diagnose the machining errors. Thus,
the capabilities of these modules increase the
amount of autonomy given to the WEDM machine.
Huang and Liao [111] have also indicated the
importance of the operator assist-ance and fault
diagnostics systems for the WEDM pro-cess. They
proposed a prototype artificial neural network-based
expert system for the maintenance schedule and fault
diagnosis of the WEDM. Dekeyser et al. [112]
developed a thermal model integrated with an expert
system for predicting and controlling the thermal
overload experienced on the wire. Although the
model increases the level of machine autonomy, it
requires a large amount of computation, which slows
down the processing speed and undermines the
online control performance.
4. Discussion and future research directions
The authors have classified the wide range
of published works relating to the WEDM process
into three major areas, namely optimizing the
process variables, monitoring and control the
process, and WEDM developments. This section
discusses the classified WEDM research areas and
the possible future research directions, illustrated in
Fig. 1.
4.1. Optimizing the process variables
The optimization of the WEDM process
often proves to be a difficult task owing to the many
regulating machining variables. A single parameter
change will influence the process in a complex way
[52]. Thus, the various factors affecting the process
has to be understood in order to determine the trends
of the process variation, as discussed in Section
4.1.1. The selection of the best combination of the
process parameters for an optimal machining
performance involves analytical and statistical
methods. However, it is very complicated to relate
the input process parameter with the output
performance measures and derive an optimal result
using a simulated algorithm. The CR, MRR and SR
are usually opted as the measures of the process
performance. Nevertheless, these methods provide
an effective means of identifying the variables
affecting the machining performance.
In addition, the modeling of the process is
also an effective way of solving the tedious problem
of relating the process parameters to the
performance measures. As mentioned in Section
4.1.2, several attempts have been carried out to
model the process investigating into the influence of
the machining parameters on WEDM performance
and identifying the optimal machining condition
from the infinite number of combinations. As a
result, it provides an accurate dimensional inspection
and verification of the process yielding a better
stability and higher productivity for the WEDM
6. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
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process. However, the complex and random nature
of the erosion process in WEDM requires the
application of deterministic as well as stochastic
techniques [61]. Therefore, the optimization of the
WEDM process will remain a key research area
matching the numerous process parameters with the
performance measures.
Fig. 1. Classification of major WEDM research
areas (corresponding section numbers are in
brackets).
4.2. Monitoring and control the process
Over the years, the monitoring and control
systems have made an important contribution in
minimizing the effect of disturbances on the
WEDM performance. The multi-parameter
machining settings have made it difficult to clearly
understand and obtain the optimal machining
conditions. It requires a control algorithm that is
often based on explicit mathematical and statistical
models to cope with the machining process.
However, the application of the fuzzy control logic
has brought about a drastic change to the
conventional way of monitoring and controlling the
WEDM process. The fuzzy control logic is able to
consider several machining variables, weigh the
significant factors affecting the process and make
changes to the machining conditions without
applying the detailed mathematical model, as
mentioned in Section 4.2.1. In addition, the
feasibility of applying the expert system capable of
giving advice and solving problems has also been
explored [110]. Such a system would greatly appeal
to the shop floor operational needs demanding
unattended WEDM operation.
The risk of the wire breakage and the bending of the
wire have also limited the efficiency and accuracy
of the WEDM process. The occurrence of the wire
breakage directly reduces the already low
machining speed affecting the overall productivity
of the machining process. Although, the control
strategies reported in Section 4.2.2 are designed to
solve the problems of wire break-age, it solely relies
on the indication of the possible Occurrence and
generates inadequate results investigating the root
cause of the wire breakage phenomenon. These
strategies may therefore be deemed to be a set-back
when machining a workpiece with variable heights
requiring a drastic change in the machining
conditions.
In addition, the wire vibration behavior and
static deflection easily influence the geometric
accuracy of the part produced. The typical solutions
to these problems are often very conservative in
nature by increasing the machining gap or reducing
the discharge energy, which is regarded to be a main
drawback for the WEDM process efficiency. Fig. 2
shows the huge amount of research work
concentrating on the improvement of the inaccuracy
caused by the wire through the application of an
adaptive control system. Jennes and Snoey [113]
believed that the traditional research purpose was
not to improve machining efficiency, but to prevent
from wire rupture during the machining process.
Hence, one possible new WEDM challenge and
future work area will be steered towards attaining
higher machining efficiency by acquiring a higher
CR and MRR with a low wire consumption and
frequency of wire breakage.
Fig. 2. Distribution of the collection WEDM
research publications.
4.3Developments
The WEDM process is a suitable
machining option in meeting the demands of today’s
modern applications. It has been commonly used in
the automotive, aerospace, mould, tool and die
making industries. WEDM applications can also be
found in the medical, optical, dental, jewellery
industries, and in the automotive and aerospace
R&D areas [114]. Its large pool of applications, as
shown in Fig. 2, is largely owed to the machining
technique, which is not restricted by the hardness,
strength or toughness of the workpiece material. As
mentioned in Section 3, the WEDM of the HSTR,
modern composite and advanced ceramic materials,
which is showing a growing tend in many
engineering applications, has also been
7. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
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experimented. It has replaced the conventional
means of machining ceramics, namely the
ultrasonic machining and laser beam machining,
which are not only costly to machine but damage
the surface integrity of the ceramic component.
However, with the introduction of over 20 non-
traditional machining processes in the past 50 years
and the rapid growth in the development of harder,
tougher and stronger workpiece materials [115], the
WEDM process inevitably has to be constantly
rejuvenated in order to compete and satisfy the
future crucial machining requirements.
In addition, the WEDM process has sought
the benefits of combining with other material
removal methods to further expand its applications
and improve the machining characteristics. The
authors have classified the WEDM machine into the
various physical characteristics, which clearly
distinguishes the different types of machine features
affecting the performance measures, machining
capacity and auxiliary facilities, as shown in Fig. 3.
One of the most practical and precision HMP
arrangements is the WEDG process used mainly to
produce small size and complicated shape thin rod,
which can be easily bent or broken by the lateral
force when using conventional grinding process.
The precision of the CNC system is also partly
responsible for the accuracy of the WEDG [116].
Therefore, the HMP processes, in particular the
WEDG process, will continue to receive intense
research attention especially in the growing field of
micro-electronics circuitry manufacturing.
There is also a major push toward an
unattended WEDM operation attaining a machining
performance level that can be only achieved by a
skilled operator. Such a goal has been partly
fulfilled through the application of the CNC to
control the machining strategies, to prevent the wire
breakage and to automate the self-threading
systems. An environmentally friendly and high-
capacity dielectric regeneration system, which
autonomously maintains the quality of the dielectric
circulating within the WEDM machine, has also
been experimented [117]. However, due
consideration still has to be given to improve the
WEDM performance and enhance the level of
automation for future integration of the EDM and
WEDM processes within the CIM environment
[118]. It would then be able to reasonably meet the
shortage of highly skilled EDM/ WEDM operators
and achieve a more cost efficient and cost effective
machining operation.
5. Conclusion
WEDM is a well-established non-
conventional material removal process capable of
meeting the diverse machining requirements posed
by the demanding metal cutting industries. It has
been commonly applied for the machining and
micro-machining of parts with intricate shapes and
varying hardness requiring high profile accuracy and
tight dimensional tolerances. However the main
disadvantage of the process is the relatively low
machining speed, as compared to the other non-
traditional machining processes such as the laser-
cutting process, largely due to its thermal machining
technique. In addition, the development of newer
and more exotic materials has challenged the
viability of the WEDM process in the future
manufacturing environment. Hence, continuous
improvement needs to be made to the current
WEDM traits in order to extend the machining
capability and increase the machining productivity
and efficiency.
The ultimate goal of the WEDM process is
to achieve an accurate and efficiency machining
operation without compromising the machining
performance. This is mainly carried out by
understanding the inter-relationship between the
various factors affecting the process and identifying
the optimal machining condition from the infinite
number of combinations. The adaptive monitoring
and control systems have also been extensively
implemented to tame the transient WEDM behavior
without the risk of wire breakages. Moreover,
several monitoring and control algorithms based on
the explicit mathematical models, expert’s
knowledge or intelligent systems have been reported
to reduce the inaccuracy caused by the vibration
behavior and static deflection of the wire. With the
continuous trend towards unattended machining
operation and automation, the WEDM process has to
be constantly improved to maintain as a competitive
and economical machining operation in the modern
tool-room manufacturing arena. Though the authors
believe that the WEDM process due to its ability to
efficiently machine parts with difficult-to-machine
materials and geometries has it own application area
unmatched by other manufacturing processes.
8. Prof. Vijay D.Patel, Dr. Rajeev V. Vaghmare / International Journal of Engineering Research
and Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.805-816
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Fig. 3. Classification of wire-cutting EDM machine.
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