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.
WEDM process parameter optimization for newly developed hybrid Al(SiC + Gr + ...ROEVER GROUPS
This document summarizes an experimental study that optimized wire electrical discharge machining (WEDM) parameters for machining a hybrid Al/(SiC + Gr + Fe2O3) metal matrix composite (MMC). Taguchi methods were used to design the experiment using an L27 orthogonal array to investigate the effects of six machining parameters (peak current, pulse-on time, pulse-off time, wire tension, feed rate, and voltage gap) on surface roughness. The experiments found that pulse-on time, current, and off-time significantly affected surface roughness, and confirmatory tests showed that using the optimized parameter combination improved the surface finish.
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
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.
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This document summarizes research on using powder mixed dielectrics in electrical discharge machining (PMEDM). It first reviews the basic material removal mechanism in EDM and important process parameters. It then discusses various dielectric categories used in EDM, including hydrocarbon oils, deionized water, and their advantages/disadvantages. The main body of the document provides a detailed review of using powder mixed with dielectric in PMEDM, focusing on how powder affects spark characteristics and machining performance based on powder material, size, and concentration. It concludes with a discussion of research trends, gaps, and challenges in industrializing PMEDM technology.
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.
The document is a dissertation submitted by Gangadharudu Talla to the National Institute of Technology Rourkela in partial fulfillment of the requirements for a Doctor of Philosophy degree in Mechanical Engineering. The dissertation investigates the powder-mixed electric discharge machining (PMEDM) of Inconel 625, a nickel-based super alloy. Numerical modeling is used to predict the temperature distribution, material removal rate, and residual stress during the PMEDM process. Experiments are then conducted to study the effects of powder materials (graphite, aluminum, and silicon) and machining parameters on material removal rate, surface integrity, and other response variables. Results are analyzed to determine the optimal powder material and process parameters
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.
WEDM process parameter optimization for newly developed hybrid Al(SiC + Gr + ...ROEVER GROUPS
This document summarizes an experimental study that optimized wire electrical discharge machining (WEDM) parameters for machining a hybrid Al/(SiC + Gr + Fe2O3) metal matrix composite (MMC). Taguchi methods were used to design the experiment using an L27 orthogonal array to investigate the effects of six machining parameters (peak current, pulse-on time, pulse-off time, wire tension, feed rate, and voltage gap) on surface roughness. The experiments found that pulse-on time, current, and off-time significantly affected surface roughness, and confirmatory tests showed that using the optimized parameter combination improved the surface finish.
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
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.
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This document summarizes research on using powder mixed dielectrics in electrical discharge machining (PMEDM). It first reviews the basic material removal mechanism in EDM and important process parameters. It then discusses various dielectric categories used in EDM, including hydrocarbon oils, deionized water, and their advantages/disadvantages. The main body of the document provides a detailed review of using powder mixed with dielectric in PMEDM, focusing on how powder affects spark characteristics and machining performance based on powder material, size, and concentration. It concludes with a discussion of research trends, gaps, and challenges in industrializing PMEDM technology.
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.
The document is a dissertation submitted by Gangadharudu Talla to the National Institute of Technology Rourkela in partial fulfillment of the requirements for a Doctor of Philosophy degree in Mechanical Engineering. The dissertation investigates the powder-mixed electric discharge machining (PMEDM) of Inconel 625, a nickel-based super alloy. Numerical modeling is used to predict the temperature distribution, material removal rate, and residual stress during the PMEDM process. Experiments are then conducted to study the effects of powder materials (graphite, aluminum, and silicon) and machining parameters on material removal rate, surface integrity, and other response variables. Results are analyzed to determine the optimal powder material and process parameters
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.
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.
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
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.
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.
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.
This document describes a study that used Response Surface Methodology (RSM) to optimize the Wire Electric Discharge Machining (WEDM) process for D-2 tool steel. RSM and a central composite design were used to develop models for how the material removal rate (MRR) responds to four machining parameters: pulse on time, pulse off time, peak current, and servo voltage. 30 experiments were conducted according to the design. The results showed that MRR increases with pulse on time and peak current, but decreases with pulse off time and servo voltage.
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 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.
effect of electrode material and geometry on edm performance for ohns dies s...INFOGAIN PUBLICATION
Modern EDM machinery is capable of machining micro-hole, thin slots, geometrically complex or hard material components, that are precise and difficult to machine, such as heat treated tool steels, composites, super alloys, etc. The studies of an experimental investigation evaluate the effects of EDM machining parameters such as MRR, EWR and Surface Roughness with two different electrode materials. The process parameters such as Input current, Pulse on time and duty cycle keeping flushing pressure constant. The full factorial design of experiment (L25) is used to study the effects of machining parameters. Investigations indicate that the output parameters of EDM increases with the increase in input current and the best machining rates are achieved with copper with through hole electrodes, better surface roughness compare to brass electrode. A brass electrode with higher input current and maximum pulse on time resulted in more EWR compared to copper electrodes. Also the increase in MRR by copper electrode, it improves the SR during Electric Discharge Machining.
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.
Experimental Study with Rotating Tool Electrode of EDM for NiAlloyIJMER
Conventional machining process has the limitation when desired surface finish and
dimensional accuracy in geometry is required in difficult to machine aerospace materials especially for
the cases of drilling holes. Non conventional advance machining processes (AMPs) are extensively used
in the industry to machine for the complex geometrical dimension along with desired surface finish in
hard materials. Electrical Discharge machining with modification for holding and rotating the
electrode has been used in the present experiment for making holes in the Nimonic alloy. This paper
investigate the influence of gap current, pulse on time, duty factor, tool electrode rpm and especially the
polarity of the machine on Material Removal Rate (MRR) and surface roughness (Ra) for machining of
Nimonic alloy. It is observed that with suitable control of input parameters of Electrical Discharge
drilling (EDD), MRR and Ra both found to be improving together from 60 to 90 mg and 4.8 to 2.9 µm
respectively which confirm the viability of using tool electrode rotation in EDM machining.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
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.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
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
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.
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
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 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
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.
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
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.
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.
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.
This document describes a study that used Response Surface Methodology (RSM) to optimize the Wire Electric Discharge Machining (WEDM) process for D-2 tool steel. RSM and a central composite design were used to develop models for how the material removal rate (MRR) responds to four machining parameters: pulse on time, pulse off time, peak current, and servo voltage. 30 experiments were conducted according to the design. The results showed that MRR increases with pulse on time and peak current, but decreases with pulse off time and servo voltage.
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 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.
effect of electrode material and geometry on edm performance for ohns dies s...INFOGAIN PUBLICATION
Modern EDM machinery is capable of machining micro-hole, thin slots, geometrically complex or hard material components, that are precise and difficult to machine, such as heat treated tool steels, composites, super alloys, etc. The studies of an experimental investigation evaluate the effects of EDM machining parameters such as MRR, EWR and Surface Roughness with two different electrode materials. The process parameters such as Input current, Pulse on time and duty cycle keeping flushing pressure constant. The full factorial design of experiment (L25) is used to study the effects of machining parameters. Investigations indicate that the output parameters of EDM increases with the increase in input current and the best machining rates are achieved with copper with through hole electrodes, better surface roughness compare to brass electrode. A brass electrode with higher input current and maximum pulse on time resulted in more EWR compared to copper electrodes. Also the increase in MRR by copper electrode, it improves the SR during Electric Discharge Machining.
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.
Experimental Study with Rotating Tool Electrode of EDM for NiAlloyIJMER
Conventional machining process has the limitation when desired surface finish and
dimensional accuracy in geometry is required in difficult to machine aerospace materials especially for
the cases of drilling holes. Non conventional advance machining processes (AMPs) are extensively used
in the industry to machine for the complex geometrical dimension along with desired surface finish in
hard materials. Electrical Discharge machining with modification for holding and rotating the
electrode has been used in the present experiment for making holes in the Nimonic alloy. This paper
investigate the influence of gap current, pulse on time, duty factor, tool electrode rpm and especially the
polarity of the machine on Material Removal Rate (MRR) and surface roughness (Ra) for machining of
Nimonic alloy. It is observed that with suitable control of input parameters of Electrical Discharge
drilling (EDD), MRR and Ra both found to be improving together from 60 to 90 mg and 4.8 to 2.9 µm
respectively which confirm the viability of using tool electrode rotation in EDM machining.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
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.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
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
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.
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
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 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
Welcome to International Journal of Engineering Research and Development (IJERD)IJERD Editor
This document provides a review of research on Electrical Discharge Machining (EDM) and its applications. It summarizes 111 research papers on EDM. The summary discusses developments in EDM, including experimental studies on machining different materials and modeling approaches like mathematical models, simulation, fuzzy logic, and artificial neural networks to optimize EDM performance. It also reviews research on Wire EDM processes and applications of modeling techniques like response surface methodology and Taguchi methods. The document concludes that research areas like dry EDM and using water as a dielectric fluid show emerging potential to further enhance EDM capabilities.
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICRO...ijiert bestjournal
Nowadays,necessity of small components is a common trend. These requirements encourage the researcher s to develop very minutest size components to fulfill the demand. The manufact uring of these type of components is a difficult ob ligation and for that various machining methods are develop to manufacture such c omponents. In this article the Electro Chemical mac hining and Electrical Discharge Machining is reviewed. We tried to summar ize the work of various researchers. The study show s that this type of machining processes gives good alternative.
Trends in Wire Electrical Discharge Machining (WEDM): A ReviewIJERA Editor
This document summarizes research on trends in wire electrical discharge machining (WEDM). It reviews several studies that investigated how WEDM process parameters affect outcomes like surface roughness, cutting speed, and material removal rate. Different materials were examined, including metals, composites, and silicon. Process parameters like pulse on-time, current, wire feed rate, and dielectric fluid composition were found to influence the results. Statistical methods like Taguchi experiments and analysis of variance were commonly used to determine significant factors and optimize the process.
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
IRJET- Experimental Investigations on Machining Characteristics of AA5754...IRJET Journal
This document presents an experimental investigation into the machining characteristics of AA5754-TiB2 metal matrix composites using wire electrical discharge machining (WEDM). Experiments were conducted using an orthogonal array to examine the effects of various WEDM parameters like pulse on time, pulse off time, servo voltage, wire feed, and wire tension on material removal rate and surface roughness. Analysis of variance was used to evaluate the significant design parameters, while signal-to-noise ratios examined the effects on the responses. The results identified an optimal combination of parameters that maximized material removal rate with minimum surface roughness. Confirmation experiments validated the proposed method.
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
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.
IRJET- Optimization of WEDM Process Parameters on Machining of AA6082/SiC Met...IRJET Journal
This document discusses optimizing the wire electrical discharge machining (WEDM) process parameters for machining an aluminum AA6082/silicon carbide (SiC) metal matrix composite. The objectives are to achieve the maximum material removal rate and minimum surface roughness. A Taguchi L9 orthogonal array experimental design is used to evaluate three process parameters (pulse on time, pulse off time, and peak current) at three levels each. The experiments are conducted on an AA6082/5% SiC composite fabricated using stir casting. Response variables of material removal rate and surface roughness are measured and multi-objective optimization is performed using Grey relational analysis.
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.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
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
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
Analysis of Machining Characteristics of Cryogenically Treated Die Steels Usi...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Investigation of mrr in wedm for wc co sintered compositeIAEME Publication
The document investigates the influence of wire electrical discharge machining (WEDM) parameters on material removal rate when machining tungsten carbide-cobalt (WC-Co) sintered composite. Experiments were conducted using a response surface methodology with five control factors (pulse on-time, pulse off-time, peak current, servo voltage, and wire tension). The results were used to derive a mathematical model to predict material removal rate and optimize the WEDM process for machining WC-Co composite.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
IRJET-Experimental Analysis Optimization of Process Parameters of Wire EDM on...IRJET Journal
This document analyzes the optimization of process parameters for wire electrical discharge machining (WEDM) of stainless steel 316L. It conducts experiments using different controllable factors like discharge current, pulse on/off time, and arc gap. Taguchi design of experiments is used to optimize for maximum material removal rate. Experiments are conducted using a copper tool on 316L stainless steel workpieces. The results are analyzed to determine the optimum parameter levels for achieving higher material removal rate and better surface finish quality during WEDM of 316L stainless steel.
Similar to Optimization of Process Parameters in Wire Electrical Discharge Machining of MMC: A Review (20)
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
Traditionally, dealing with real-time data pipelines has involved significant overhead, even for straightforward tasks like data transformation or masking. However, in this talk, we’ll venture into the dynamic realm of WebAssembly (WASM) and discover how it can revolutionize the creation of stateless streaming pipelines within a Kafka (Redpanda) broker. These pipelines are adept at managing low-latency, high-data-volume scenarios.
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
IEEE Slovenia CIS
11TH INTERNATIONAL CONFERENCE ON ELECTRICAL, ELECTRONIC AND COMPUTING ENGINEERING
3-6 June 2024, Niš, Serbia
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
New techniques for characterising damage in rock slopes.pdf
Optimization of Process Parameters in Wire Electrical Discharge Machining of MMC: A Review
1. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 34 | P a g e
Optimization of Process Parameters in Wire Electrical Discharge
Machining of MMC: A Review
J.M.Pujara1
, Dr.A.V.Gohil2
1
Ph.D Scholar, School of Engineering, RK University and Assistant Professor, Government Engineering
College, Rajkot, Gujarat, India
2
Associate Professor, Shantilal Shah Engineering College, Bhavnagar- 364060, Gujarat, India
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. 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.
Keywords - Wire EDM, Metal Matrix Composite, Optimization, MRR, Surface roughness
I. INTRODUCTION
Metal Matrix Composites have proven to be
significant highly developed materials that provide
as alternatives to many conventional materials,
mostly when light-weight and high strength parts are
needed such as in the automotive, aerospace, defense
and other industries. MMCs have found many
successful industrial applications in recent past as
high-technology materials due to their exceptional
properties such as high strength-to-weight ratio, high
toughness, lower value of coefficient of thermal
expansion and capability of operating at elevated
temperatures. Processed MMC cause serious tool
wear due to the presence of abrasive particles and
thus reduced tool life when machined using
conventional means. Wire - EDM seems to be a
better choice as it confirms to easy control and can
machine intricate and complex shapes Garg et al.
[1].
1.1 Overview of Wire - EDM
Wire EDM (Vertical EDM's kid brother), is not
the new kid on the block. It was introduced in the
late 1960s', and has revolutionized the tool and die,
mold, and metalworking industries. It is probably the
most exciting and diversified machine tool
developed for this industry in the last fifty years, and
has numerous advantages to offer. WEDM is a spark
erosion process used to produce complex two and
three dimensional shapes through electrically
conductive work pieces. The wire does not touch the
work piece, so there is no physical pressure imparted
on the work piece compared to grinding wheels and
milling cutters. A power supply delivers high-
frequency pulses of electricity to the wire and the
work piece and material is removed as a result of
high energy discharge subjected on the work piece.
WEDM has become an important non-traditional
machining process, widely used in the aerospace,
nuclear and automotive industries. As WEDM
process provides an effective solution for machining
hard materials (like titanium, ceramics, zirconium
and tungsten carbide) with intricate shapes and
profiles Kozak et al. [2].
1.2 Wire – EDM process parameters
The most common process parameters and
performance measures used by various researchers
in their research work regarding optimization of
Wire - EDM process is shown in Figure 1.
RESEARCH ARTICLE OPEN ACCESS
2. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 35 | P a g e
Fig-1: Process parameters and output (response)
II. WIRE CUT EDM ON COMPOSITES
This part discusses the capability of the Wire -
EDM improvement in the machining of the different
advanced materials.
2.1 Recent MMCs Materials
Wire EDM is considered as an useful and cost-
effective tool in the machining of metal matrix
composite among the different material removal
processes. Several comparative studies have been
made in the processing of metal matrix composites
(MMC). These studies showed that WEDM yields
better cutting edge quality and has better control of
the process parameters with fewer workpiece surface
damages. Ganpatrao et al. [3] attempted to study the
determination of material removal rate of WEDM of
metal matrix composites using dimensional analysis.
They proposed semi-empirical model of MRR in
WEDM based on thermo physical properties of the
work piece and pulse-on time, average gap voltage.
An empirical model based on response surface
method was developed. Lal et al. [4] conducted an
experimental study on Wire electrical discharge
machining of AA7075/SiC/Al2O3 hybrid composite
fabricated by inert gas-assisted electromagnetic stir-
casting process. The objective of the paper was to
investigate the effect of WEDM process parameters
like discharge duration, pulse interval time,
discharge current and the wire drum speed on the
kerf width while machining newly developed hybrid
metal matrix composite (Al7075/7.5 % SiC/7.5%
Al2O3). The discharge current has most significance
on kerf than discharge duration. Rozenek [5]
analyzed the electrical discharge machining
characteristics of metal matrix composites. They
studied the influence of discharge current, pulse-on
time, pulse-off time and voltage on the machining
feed rate and surface roughness during WEDM of
metal matrix composite AlSi7Mg/SiC and
AlSi7Mg/Al2O3. The analysis of results shows that
maximum cutting speed of AlSi7Mg/SiC and
AlSi7Mg/Al2O3 composites are obtained to be
approximately 3 times and 6.5 times lower than the
cutting speed of aluminum alloy. Samy et al. [6]
developed a mathematical modeling for wire
electrical discharge machining of Aluminium-
Silicon Carbide composites. They optimized WEDM
characteristics such as the MRR, cutting speed and
the surface roughness was developed. The process
parameters considered are the average machining
voltage, the pulse frequency, the work piece height,
the kerf size and the percentage volume fraction of
SiC present in the aluminum matrix. Satish Kumar et
al. [7] presented an experimental study of wire
electrical discharge machining characteristics of
Al6063/SiCp composites. In this work, the effect of
WEDM parameters such as pulse on time, pulse off
time, gap voltage and wire feed on material removal
rate and surface roughness in MMCs consisting of
Al6063 and SiCp are given. Regression equations
are developed to predict the output parameters for
Al6063 and composites.
2.2 Highly developed ceramic materials
The WEDM process has also evolved as one of
the most promising alternatives for the machining of
the advanced ceramics. Sanchez et al. [8] provided a
literature survey on the EDM of advanced ceramics,
which have been commonly machined by diamond
grinding and lapping. In the same paper, they studied
the feasibility of machining boron carbide (B4C) and
silicon infiltrated silicon carbide using EDM and
WEDM. Cheng et al. [9] also evaluated the
possibility of machining ZrB2 based materials using
EDM and WEDM, whereas Matsuo and Oshima
[10] examined the effects of conductive carbide
content, namely niobium carbide and titanium
carbide on the CR and surface roughness of
zirconium ceramics (ZrO2) during WEDM. Lok and
Lee [11] have successfully WEDMed sialon 501 and
aluminium oxide– titanium carbide (Al2O3–TiC).
However, they realized that the MRR is very low as
compared to the cutting of metals such as alloy steel
SKD-11 and the surface roughness is generally
inferior to the one obtained with the EDM process.
Dauw et al. [12] explained that the MRR and surface
roughness are not only dependent on the machining
parameters but also on the material of the part
2.3 Recent applications in tooling design
WEDM has been gaining wide acceptance in the
machining of the various materials used in modern
tooling applications. Several authors [13,14] have
investigated the machining performance of WEDM
in the wafering of silicon and machining of
compacting dies made of sintered carbide. The
feasibility of using cylindrical WEDM for dressing a
rotating metal bond diamond wheel used for the
3. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 36 | P a g e
precision form grinding of ceramics has also been
studied [15]. The results show that the WEDM
process is capable of generating precise and intricate
profiles with small corner radii but a high wear rate
is observed on the diamond wheel during the first
grinding pass. Such an initial high wheel wear rate is
due to the over-protruding diamond grains, which do
not bond strongly to the wheel after the WEDM
process [16]. The WEDM of permanent NdFeB and
‘soft’ MnZn ferrite magnetic materials used in
miniature systems, which requires small magnetic
parts, was studied by comparing it with the laser-
cutting process [17]. It was found that the WEDM
process yields better dimensional accuracy and SF
quality but has a slow CR, 5.5 mm/min for NdFeB
and 0.17 mm/min for MnZn ferrite. A study was also
done to investigate the machining performance of
micro-WEDM used to machine a high aspect ratio
meso-scale part using a variety of metals including
stainless steel, nitronic austentic stainless, beryllium
copper and titanium [18].
III. OPTIMIZATION OF WIRE - EDM
PROCESS
This segment provides a study on the several
machining strategies connecting the design of the
process input factors and the mathematical modeling
for the optimization of performance measure
parameters. The most effectual machining strategy is
finalized by identifying the different factors
affecting the Wire- edm process and looking for the
different behavior of obtaining the most favorable
machining condition.
3.1 Design of machining parameters
The settings for the different machining
parameters necessary in the Wire - edm process play
a key role in producing an most favorable machining
performance. This part shows some of the logical
and arithmetical methods used to study the effects of
the parameters on the output quality characteristics
such as Surface roughness, kerf width and Cutting
Rate.
3.1.1 Factors influencing the output
parameters
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 [19]. Suziki and
Kishi [20] studied the reduction of discharge energy
to yield a better surface roughness, while Several
authors [21] have also studied the evolution of the
wire tool performance affecting the machining
accuracy, costs and performance measures.
3.1.2 Machining parameters effects 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. [22] classified the various potential
factors affecting the WEDM performance measures
into five major categories namely the different
properties of the workpiece 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. [23]
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
voltage, servo reference voltage, electrical
capacitance and table speed are the critical
parameters for the estimation of the CR and SF.
Huang et al. [24] argued that several published
works [25] 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 workpiece surface affect the CR
and SF significantly. The effects of the discharge
energy on the CR and SF of a MMC have also been
investigated [26].
3.1.3. Machining parameters effects on
the MRR
The effects of the machining parameters on the
volumetric MRR have also been considered as a
measure of the machining performance. Scott et al.
[27] used a factorial design requiring a number of
experiments to determine the most favorable
combination of the WEDM parameter. They found
that the discharge current, pulse duration and pulse
frequency are the significant control factors affecting
the MRR and SF, while the wire speed, wire tension
and dielectric flow rate have the least effect. Liao et
al. [28] proposed an approach of determining the
parameter settings based on the Taguchi quality
design method and the analysis of variance. The
results showed that the MRR and SF are easily
influenced by the table feed rate and pulse on-time,
which can also be used to control the discharging
frequency for the prevention of wire breakage.
Huang and Liao [29] presented the use of Grey
relational and S/N ratio analyses, which also display
similar results demonstrating the influence of table
4. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 37 | P a g e
feed and pulse on-time on the MRR. An
experimental study to determine the MRR and SF
for varying machining parameters has also been
conducted [30].The results have been used with a
thermal model to analyze the wire breakage
phenomena.
3.1.4. Machining parameters effects on
the surface roughness
There are also a number of published works that
solely study the effects of the machining parameters
on the WEDMed surface. Gokler [31] studied the
selection of the most suitable cutting and offset
parameter combination to get a desired surface
roughness for a constant wire speed and dielectric
flushing pressure. Tosun et al. [32] investigated the
effect of the pulse duration, open circuit voltage,
wire speed and dielectric flushing pressure on the
WEDMed workpiece surface roughness. It was
found that the increasing pulse duration, open circuit
voltage and wire speed increases with the surface
roughness, whereas the increasing dielectric fluid
pressure decreases the surface roughness. Anand
[33] used a fractional factorial experiment with an
orthogonal array layout to obtain the most desirable
process specification for improving the WEDM
dimensional accuracy and surface roughness.
Spedding and Wang [34] optimized the process
parameter settings by using artificial neural network
modeling to characterize the WEDMed workpiece
surfaces.
IV. FEASIBILITY OF METAL MATRIX
COMPOSITES
Intensive research in MMCs started about thirty
years ago to meet the increasing requirements of
properties in aerospace materials to achieve higher
speed and higher temperature engines for higher
efficiencies. Most of these MMCs were used in
aerospace applications where weight savings were of
paramount importance, and to some extent in
selected weapons systems, where cost was hardly of
any concern. During the last few years, several
developments have occurred in MMCs which have
great relevance to India. For instance, the costs of
metal-matrix fiber reinforced composites have come
down from several hundred thousand dollars per
pound to the order of a thousand dollars per pound at
this time due to the decrease in costs of continuous
fibers. The continuous fibre reinforced MMCs,
therefore, still remain quite expensive for
widespread use in countries like India, except for
certain critical applications where enormous savings
in energy or resources can be made: However, there
has been a more dramatic decrease in the cost of
metal-matrix discontinuous fibre/particulate
composites. The costs of particulate composites like
aluminium-silicon carbide have come down to the
level of two to ten dollars per pound due to the
feasibility of using inexpensive particulate
reinforcements and the possibility of using
conventional casting processes to produce these
composites. These composites can be made at even
lower costs due to the lower costs of highly skilled
manpower in India. The following are the list of
selected organization working on MMCs in India.
National Physical Laboratory, CSIR, New
Delhi
Indian Institute of Technology, New Delhi
Indian Institute of Technology, Kanpur
Regional Research Laboratory, CSIR,
Bhopal
Regional Research Laboratory, CSIR,
Trivandrum
National Aeronautical Laboratory, CSIR,
Bangalore
Vikram Sarabhaa Space Centre,
Trivandrum
Indian Institute of Science, Bangalore
Banaras Hindu University, Varanasi
University of Roorkee, Roorkee
Defense Metallurgical Research
Laboratory, Hyderabad
Hindustan Aeronautics, Bangalore
Indian Institute of Technology, Bombay
V. MMCS FABRICATION METHODS
Fabrication of MMCs is the primary processing
route of its production. A basic classification, about
the technological methods for MMCs, takes account
of the state where the constituents during the
primary cycle of production. Fabrication methods of
Metal Matrix Composites can be mostly divided into
three categories.
5.1 Liquid state Processing
Processing of Metal Matrix Composite using
liquid state find wide acceptance as it involves lower
cost for getting liquid metals than metal powder.
Various complex shapes using liquid metals can be
produce with significant ease by adopting methods
already developed in the casting industry. Some
techniques documented by researchers are
infiltration, dispersion, squeeze casting, stir casting
and compo-casting etc. On the other hand liquid
phase fabrication also suffers from a number of
limitations that consist of lack of reproducibility
associated with imperfect control of the processing
parameters and some adverse chemical reactions at
the interface of the reinforcement and the liquid
metal.
5.2 Solid phase fabrication
Solid states processing of MMCs are generally
used to get the maximum mechanical and physical
properties. Excellent grained control over the
composite microstructure and the reinforcement
distribution can be easily obtained by this process.
5. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 38 | P a g e
Mostly the discontinuous reinforcement Metal
Matrix Composites are processed in this route. In
present day some adopted methods of MMCs are
diffusion bonding and powder metallurgy.
5.3 Vapor phase fabrication
Vapor state processing is a key process where
the matrix is deposited from the vapor stage into
individual reinforcement parts of the constituent. It
may be noted that there is tiny or no mechanical
disorder of the interfacial area and large bond in
between reinforcement with no any chemical
reaction. The matrix is deposited by plasma spraying
or by chemical vapor deposition.
VI. OPTIMIZATION METHODOLOGY
Various optimization techniques used by the
various researchers’ for improvement and
optimization of performance measures of WEDM
machining on MMCs.
Following are the summary of experimental
work carried out by various researchers on Wire-
EDM machining of Metal Matrix Composites,
effects of machining parameters on output response
quality characteristics and their conclusions.
The Material Removal Rate, Cutting Speed and
Surface Roughness were analyzed by A. Pramanik
[35] for AlSi7Mg/20%SiC reinforced MMC using
different non - traditional machining. He analyzed
that Vaporization, Chemical dissolution and
Mechanical erosion are the most important material
removal mechanisms occur during machining. The
thermal degradation and the presence of
reinforcement particles mainly break the machined
surface
Thella Babu rao et al. [36] inspected the effect
of machining parameter such as Pulse-on time,
Pulse-off time and Wire tension on Surface
roughness, Metal removal rate and Wire wear ratio
of Al7075/SiCp MMC using Wire-EDM. Response
surface methodology is used to build up the
empirical models for these WEDM responses. They
interpreted that machining responses are conflicting
in nature. The problem is formulated as a multi-
objective optimization problem and is solved using
the Non-dominated Sorting Genetic Algorithm-II.
The MRR, TWR, SR and Circularity were
analyzed by D. Puhan et al. [37] using four
machining parameters such as Discharge current,
Pulse duration, Duty cycle and Flushing pressure
and two material parameters (weight fraction of
silicon carbide in the composite and mesh size)
during the machining of AlSiCp by EDM. The
fabrication of MMC was carried out by PM Route. A
hybrid approach combining Principal component
analysis and Fuzzy inference system coupled with
taguchi method to simultaneously optimize multiple
responses for desirable parametric conditions.
The Cutting Width (Kerf) were analyzed by
Pragya Shandilya et al. [38] using process
parameters such as Servo voltage, Pulse on time,
Pulse off time and Wire feed rate during the
machining of SiCp/6061Al MMC by WEDM. The
MMC of Aluminium 6061 reinforced with 10% of
SiC particles (by Weight) were prepared by Stir
casting method. A mathematical model was
developed to analyzed the effects of WEDM
parameters using Response Surface Methodology.
ANOVA results show that voltage and wire feed rate
are highly significant parameters and pulse-off time
is less significant. Pulse-on time has insignificant
effect on kerf.
D. Satishkumar et al. [39] investigated the effect
of wire electrical discharge machining parameters
such as Pulse-on time, Pulse-off time, Gap voltage
and Wire feed on Material removal rate and Surface
roughness in Al6063/SiCp MMC. The Al6063 is
reinforced with SiCp in the form of particles with
5%, 10% and 15% volume fractions. The results
were analyzed using analysis of variance and
response graphs. It was found that different
combinations of WEDM process parameters are
required to achieve higher MRR and lower SR. It
was also found that the increase in volume
percentage of SiC resulted in decreased MRR and
increased SR.
K.M.Patel et al. [40] investigated the inter-
relationships of various EDM machining parameters
namely discharge current, pulse-on time, duty cycle
and gap voltage on the metal removal rate (MRR),
electrode wear ratio (EWR) and surface roughness
using the response surface methodology (RSM) on
Al2O3–SiCw–TiC ceramic composite. The
experimental results reveal that discharge current,
pulse-on time and duty cycle significantly affected
MRR and EWR while discharge current and pulse-
on time affected the surface roughness.
S. Habib [41] carried out experiments on
conductive metal matrix composite Aluminium
silicon carbide. A comprehensive mathematical
model was developed for correlating the interactive
and higher order influence of various electrical
discharge machining parameters e.g. the pulse on
time, peak current, average gap voltage and SiC
percentage (5, 10, 20 and 25) on the respective
material removal rate, electrode wear ratio, gap size
and surface roughness using RSM. The adequacy of
the above the proposed models have been tested
through the analysis of variance.
VII. DISCUSSIONS AND CONCLUSIONS
After a detailed analysis of the literature, the
following conclusions can be drawn.
The literature review clearly indicates that the
Wire EDM on composites are widely reported
in literatures. Silicon carbide and Aluminum
6. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 39 | P a g e
oxide reinforced composites widely studied in
the literatures. Investigation in Wire- EDM on
particulate reinforced Metal Matrix
Composites is still increasing through as it has
made superior evolution in few areas.
The various applications of Wire-EDM have
been found in Aerospace, Automobile, Medical
and die manufacturing industries, where
precise dimensions is the prime objective.
Machining of Al/SiC can be made economical
by suitably selecting the machining
parameters.
The attendance of reinforced particles adds
extra difficulty and makes the machining
process different from that of monolithic
matrix material. There are still deficiencies in
appreciative the mechanisms of most of the
machining processes due to the different
capacities of removing reinforced particles.
Tool breaking, tool wear and recast layer are
the main troubles observed in Wire – EDM.
Various researchers have made attempts in the
machining of Al/SiC in WEDM. The process
remains still challenging due to the
Distribution and orientation of reinforcement
in the metal matrix and Non homogeneous and
anisotropic nature of composite as a whole.
While machining of Aluminium Matrix
Composites, Wire breakages are initiate to
pose limitations on the cutting speed. Work
regarding different wire material has not been
fully explored.
It is also found that most of the research work
has been carried out on improvement and
optimization of same performance measures
like MRR, Surface roughness for different
materials, but some performance measures like
Gap current, dimensional deviation, hardness,
etc. are either not much focused or not focused
yet. So, this area is yet to be explored more.
Most of the researchers have concentrated on
optimization of single quality characteristic
while in present industries, high productivity
and product quality with low production cost
are important. To achieve that simultaneously,
multi response optimization of machining
process is required. This area can be taken up
for further research as they required more
attention.
Acknowledgements
I express my deep sense of gratitude to
Dr.A.V.Gohil, Head & Associate professor,
Shantilal Shah Engineering College at Bhavnagar for
providing guidance for the development of this
work.
REFERENCES
[1] Garg, M. P., Jain A. and Bhushan, G.(2012)
Modeling and multi objective optimization of
process parameters of WEDM using non
dominated sorting algorithm. Proceedings of
Institution of Mechanical Engineers, Part B,
Journal of Engineering Manufacture,
226(12):1986-2001
[2] Kozak, J., Rajurkar, K.P. and Chandarana,
N.(2004) Machining of low electrical
conductive materials by wire electrical
discharge machining (WEDM) process.
Journal of Materials Processing Technology
149:266-276
[3] Nilesh Ganpatrao Patil and P. K. Brahmankar.
(2010) Determination of material removal rate
in wire electro-discharge machining of metal
matrix composites using dimensional
analysis. The International Journal of
Advanced Manufacturing Technology. Vol.
48: 537-555
[4] Shyam Lal, Sudhir Kumar, Z. A. Khan, and
A. N. Siddiquee (2014) Wire electrical
discharge machining of AA7075/SiC/Al2O3
hybrid composite fabricated by inert gas-
assisted electromagnetic stir-casting process.
Journal of the Brazilian Society of
Mechanical Sciences and Engineering. Vol
36:335-346
[5] M. Rozenek, J. Kozak, L. Dąbrowski, K. and
Lubkowski (2001) Electrical discharge
machining characteristics of metal matrix
composites. Journal of Materials Processing
Technology. Vol 109: 367–37015
[6] Samy Ebeid, Raouf Fahmy and Sameh Habib
(2004) Mathematical Modeling for Wire
Electrical Discharge Machining of
Aluminum-Silicon Carbide Composite,
Proceedings of the 34th International
MATADOR Conference:147-152
[7] D. Satishkumar, M. Kanthababu, V.
Vajjiravelu, R. Anburaj, N. Thirumalai
Sundarrajan and H. Arul (2012) Investigation
of wire electrical discharge machining
characteristics of Al6063/SiCp composites.
The International Journal of Advanced
Manufacturing Technology, Vol. 63: 1191-
1202
[8] J.A. Sanchez, I. Cabanes, L.N. Lopez de
Lacalle, A. Lamikiz (2001). Development of
optimum electro discharge machining
technology for advanced ceramics, Inter. J.
Adv. Manuf. Technol. 18 (12): 897–905
[9] Y.M. Cheng, P.T. Eubank, A.M. Gadalla
(1996) Electrical discharge machining of
ZrB2-based ceramics. Mater. Manuf.
Processes 11 (4): 565–574
7. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 40 | P a g e
[10] T. Matsuo, E. Oshima (1992) Investigation on
the optimum carbide content and machining
condition for wire EDM of zirconium
ceramics. Ann. CIRP 41 (1): 231–234
[11] Y.K. Lok, T.C. Lee (1997) Processing of
advanced ceramics using the wire-cut EDM
process. J. Mater. Process. Technol. 63 (1–3):
839–843
[12] D.F. Dauw, C.A. Brown, J.P. Van
griethuysen, J.F.L.M. Albert (1990) Surface
topography investigations by fractal analysis
of spark-eroded, electrically conductive
ceramics. Ann. CIRP 39 (1): 161–165
[13] Y.F. Luo, C.G. Chen, Z.F. Tong (1992)
Investigation of silicon wafering by wire
EDM. J. Mater. Sci. 27 (21): 5805–5810.
[14] G.N. Levy, R. Wertheim (1988) EDM-
machining of sintered carbide compacting
dies. Ann. CIRP 37 (1): 175–178
[15] B.K. Rhoney, A.J. Shih, R.O. Scattergood,
J.L. Akemon, D.J. Grant, M.B. Grant (2002)
Wire electrical discharge machining of metal
bond diamond wheels for ceramic grinding,
Inter. J. Mach. Tools Manuf. 42 (12):1355–
1362
[16] B.K. Rhoney, A.J. Shih, R.O. Scattergood, R.
Ott, S.B. McSpadden (2002) Wear
mechanism of metal bond diamond wheels
trued by wire electrical discharge machining.
Wear 252 (7–8) : 644–653
[17] A. Kruusing, S. Leppavuori, A. Uusimaki, B.
Petretis, O. Makarova (1999)
Micromachining of magnetic materials.
Sensors Actuators 74 (1–3) : 45–51
[18] G.L. Benavides, L.F. Bieg, M.P. Saavedra,
E.A. Bryce (2002) High aspect ratio meso-
scale parts enables by wire micro-EDM.
Microsys. Technol. 8 (6): 395–401
[19] G.A. Alekseyev, M.V. Korenblum (1989)
Analysis of the Conditions for the High
Efficiency Wire Cut EDM. Proceedings of the
Ninth International Symposium for Electro-
Machining (ISEM- 9), Nagoya, Japan.
[20] Y. Suziki, M. Kishi (1989) Improvement of
Surface Roughness in wire EDM.
Proceedings of the Ninth International
Symposium for Electro-Machining (ISEM-9),
Nagoya, Japan.
[21] D.F. Dauw, L. Albert (1992) About the
evolution of wire tool performance in wire
EDM. Ann. CIRP 41 (1): 221–225
[22] R. Konda, K.P. Rajurkar, R.R. Bishu, A.
Guha, M. Parson (1999) Design of
experiments to study and optimize process
performance. Inter. J. Qual. Reliab. Manage.
16 (1): 56–71
[23] Y.S. Tarng, S.C. Ma, L.K. Chung (1995)
Determination of optimal cutting parameters
in wire electrical discharge machining. Inter.J.
Mach. Tools Manuf. 35 (12): 1693–1701
[24] J.T. Huang, Y.S. Liao, W.J. Hsue (1999)
Determination of finish-cutting operation
number and machining-parameters setting in
wire electrical discharge machining. J. Mater.
Process. Technol. 87 (1–3): 69–81
[25] Y.S. Tarng, S.C. Ma, L.K. Chung (1995)
Determination of optimal cutting parameters
in wire electrical discharge machining. Inter,
J. Mach. Tools Manuf. 35 (12): 1693–1701
[26] M. Rozenek, J. Kozak, L. Dabrowski, K.
Lubkowski (2001) Electrical discharge
machining characteristics of metal matrix
composites. J. Mater. Process. Technol. 109
(3): 367–370
[27] D. Scott, S. Boyina, K.P. Rajurkar (1991)
Analysis and optimization of parameter
combination in wire electrical discharge
machining. Inter. J. Prod. Res. 29 (11): 2189–
2207
[28] Y.S. Liao, J.T. Huang, H.C. Su (1997) A
study on the machining parameters
optimization of wire electrical discharge
machining. J. Mater. Process. Technol. 71 (3):
487–493
[29] J.T. Huang, Y.S. Liao (2003) Optimization of
machining parameters of wire-EDM based on
grey relational and statistical analyses. Inter.
J. Prod. Res. 41 (8): 1707–1720
[30] K.P. Rajurkar, W.M. Wang (1993) Thermal
modelling and on-line monitoring of wire-
EDM, J. Mater. Process. Technol. 38 (1–2):
417–430
[31] M.I. Gokler, A.M. Ozanozgu (2000)
Experimental investigation of effects of
cutting parameters on surface roughness in
the WEDM process, Inter. J. Mach. Tools
Manuf. 40 (13): 1831–1848
[32] N. Tosun, C. Cogun, A. Inan (2003) The
effect of cutting parameters on workpiece
surface roughness in wire EDM. Machining
Sci. Technol. 7 (2): 209–219
[33] K.N. Anand (1996) Development of process
technology in wire-cut operation for
improving machining quality. Total Quality
Management 7 (1): 11–28
[34] T.A. Spedding, Z.Q. Wang (1997) Parametric
optimization and surface characterization of
wire electrical discharge machining process.
Precision Eng. 20 (1): 5–15
[35] A. Pramanik (2014) Developments in the non
– traditional machining of particle reinforced
metal matrix composites. International journal
of machine tools and manufacture –
Elsevier.86: 44-61
[36] Thella Babu Rao, A. Gopala Krishna
(2014)Selection of optimal process
8. J.M.Pujara Int. Journal of Engineering Research and Applications www.ijera.com
ISSN: 2248-9622, Vol. 5, Issue 7, (Part - 2) July 2015, pp.34-41
www.ijera.com 41 | P a g e
parameters in WEDM while machining
Al7075/SiCp metal matrix composites. The
International Journal of Advanced
Manufacturing Technology – Springer.73:
299-314
[37] Debaprasanna Puhan, Siba Sankar Mahapatra,
Jambeswar Sahu, Layatitdev Das (2013) A
hybrid approach for multi-response
optimization of non-conventional machining
on AlSiCp MMC, Journal of international
Measurement confederation - elsevier.46:
3581-3592
[38] Pragya Shandilya, N.K.Jain, P.K.Jain (2012)
Parametric optimization during wire electrical
discharge machining using response surface
methodology. Procedia engineering –
Elsevier.38: 2371-2377
[39] D. Satishkumar, M. Kanthababu, V.
Vajjiravelu, R. Anburaj, N. Thirumalai
Sundarrajan, H. Arul. (2011) Investigation of
wire electrical discharge machining
characteristics of Al6063/SiCp composites.
The International Journal of Advanced
Manufacturing Technology –
Springer.56:975-986
[40] Patel KM, Pandey PM, Rao PV. (2011) Study
on Machinabilty of Al2O3 Ceramic
Composite in EDM Using Response Surface
Methodology. J Engineering Mater Technol,
Trans ASME.133(2): 1-10.
[41] Habib SS.(2009) Study of the parameters in
electrical discharge machining through
response surface methodology approach. Appl
Mathematical Modeling.33(12): 4397–407