Today’s Mechanical Engineering field is growing rapidly in designing techniques to manufacture Splines and Gears. Over the decades, numerous methods and manufacturing processes have been used in making the various kinds of Splines based on various criteria, including applications, reliability, life time, processing time and manufacturing cost. This work is also carried out with the same notion of reviewing of manufacturing an External Involute Spline cutting tool using Wire Electrical Discharge Machining process and Vertical Milling Machine. Wire electrical discharge machining (WEDM) is an extremely accurate type of manufacturing process. This technique was commercially developed in the 1970s. Spline is a long flexible strip of metal/plastic/wood used to produce the curve through the known set of data points. The curved shape of strip is obtained by pulling it into the transverse direction using the lead weights or pegs.
The Wire Electric Discharge Machining (WEDM) process involves a thin metallic wire being fed through upper and lower guides onto a submerged workpiece. Electrical discharges occur between the wire electrode and workpiece, melting and removing small amounts of material. Key parameters that affect the WEDM process include voltage, current, pulse on/off times, wire feed rate, and dielectric fluid properties. WEDM can cut hard metals and complex shapes for applications in aerospace, electronics, and die/mold manufacturing.
Research for the development of the roll-to-roll printing process in lieu of the existing
semiconductor process is actively underway. The roll-to-roll printing system can enable electronic
devices to be mass-produced at low cost. This study was conducted to develop the manufacturing
technology of the printing roll used in the printing process of electronic devices. The indirect laser
engraving technology was used to create printable roll made of chrome-coated roll after coating the
surface of the steel roll with copper and polymer, ablating the polymer on the surface of the roll, and
etching the roll. The 3-dimensional laser scanner and roll rotating systems were constructed, and the
system control program was developed. We used 100W-grade fiber laser, 3-dimensional laser
scanner, and 3-axis moving stage system with a rotating axis. We derived the optimal conditions by
performing laser patterning experiments, and we were able to secure the minimum line width of 24 ㎛
by using the developed 3-dimensional laser scanner system.
A Review on Parametric Optimization in Wire Electric Discharge MachiningIJSRD
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters, include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Optimization of process parameters is necessary to reduce cost and time of manufacturing. Various optimization and relation finding methods are shown here which are frequently used by researchers. Few conclusions based on existing literature have been extracted from existing literature on optimization of WEDM process parameters.
Microstructure anlaysis and enhancement of nodular cast iron using digital im...eSAT Journals
Abstract Digital image processing is the technique to process pixel variations on digital images. This paper employs the digital image processing procedure for microstructure analysis and enhancement of nodular cast iron properties inorder to determine the quality factors. This processing made to sharpen and enhance the microstructure before quantitative analysis. This analysis taken in the analog form of nodular cast iron was performed manually such that, it is time consuming for multiple set of images. To avoid this criteria probably, Digital Image Processing techniques are being used. Often the nodular cast iron images are corrupted or defected during transmission by impulse noise which is often filtered using median filters. In this paper, some of processing steps as pre-processing, segmentation, filtering process and edge detection are done on these images for effective and lossless transmission ensuring the counting of nodules in microstructure and detailed study of grain properties that correlates with the mechanical properties such as ductility, malleability and brittleness. Only 30% restoration of image applicable to an acceptable level is limited. A new filtering method – Resolution Based Median Filter (RBMF) is proposed which achieves more than 95% restoration of nodular cast iron images to an acceptable level. This method optimizes further microstructure analysis of grain smoothening and grain boundary detection using finite element simulation model by varying the intensity level of images. Keywords – Digital Image Processing, Material Microstructure, Edge Detection, Grain Boundary, Resolution Based Median Filter (RBMF).
The document is a project report submitted by four students to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering. The report investigates optimizing the wire electrical discharge machining (WEDM) process parameters using Taguchi methods and grey relational analysis. It includes sections on the introduction of WEDM, literature review, work undertaken including the experimental setup and design, results and discussion of optimizing material removal rate, surface roughness and electrode consumption, and conclusions. The goal is to determine the optimal process parameters to achieve higher machining rates with the desired accuracy and minimal surface damage using statistical analysis techniques.
Characterization of Residual Energy Loss and Damage Prediction of wire Rope w...IJERDJOURNAL
ABSTRACT:- The Characterization of residual energy loss of wires extracted from wire rope of type 19x7 immersed in 30% H2SO4 was investigated in this paper. The results obtained from tensile tests on virgin and corroded specimens show a decrease in residual energy as function of immersion hours (8h, 16h, 24h, 32h and 40h). This progressive decrease of energy allowed us to develop a method to calculate damage evolution due to corrosion. Thereafter, and with the establishment of the damage, three stages of damage are distinguished and the value of the critical life fraction is identified, which predict the time of the damage and thus to intervene at the appropriate time before the risk of failure becomes risky.
Modelling of next zen memory cell using low power consuming high speed nano d...eSAT Journals
Abstract Hybrid SET-CMOS circuits which syndicate the assets of both the SET [Single Electron Transistor] and CMOS depicts highest possibilities to be incorporated in practical implementation for future low power VLSI/ULSI configurations. The proposed work is an attempt based on SET-CMOS hybrid circuit to realize the next gen simple Memory Cell. The authors adhered to MIB model for SET and BSIM4 model for CMOS in realizing the complex cell. The maneuver of the proposed circuit is verified subsequently in standard environment. The outcomes are in good trade off with the conventional statistics of existing memory cell. Keywords: SET, SED, Hybrid CMOS-SET, MIB and Memory Cell
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
The Wire Electric Discharge Machining (WEDM) process involves a thin metallic wire being fed through upper and lower guides onto a submerged workpiece. Electrical discharges occur between the wire electrode and workpiece, melting and removing small amounts of material. Key parameters that affect the WEDM process include voltage, current, pulse on/off times, wire feed rate, and dielectric fluid properties. WEDM can cut hard metals and complex shapes for applications in aerospace, electronics, and die/mold manufacturing.
Research for the development of the roll-to-roll printing process in lieu of the existing
semiconductor process is actively underway. The roll-to-roll printing system can enable electronic
devices to be mass-produced at low cost. This study was conducted to develop the manufacturing
technology of the printing roll used in the printing process of electronic devices. The indirect laser
engraving technology was used to create printable roll made of chrome-coated roll after coating the
surface of the steel roll with copper and polymer, ablating the polymer on the surface of the roll, and
etching the roll. The 3-dimensional laser scanner and roll rotating systems were constructed, and the
system control program was developed. We used 100W-grade fiber laser, 3-dimensional laser
scanner, and 3-axis moving stage system with a rotating axis. We derived the optimal conditions by
performing laser patterning experiments, and we were able to secure the minimum line width of 24 ㎛
by using the developed 3-dimensional laser scanner system.
A Review on Parametric Optimization in Wire Electric Discharge MachiningIJSRD
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters, include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Optimization of process parameters is necessary to reduce cost and time of manufacturing. Various optimization and relation finding methods are shown here which are frequently used by researchers. Few conclusions based on existing literature have been extracted from existing literature on optimization of WEDM process parameters.
Microstructure anlaysis and enhancement of nodular cast iron using digital im...eSAT Journals
Abstract Digital image processing is the technique to process pixel variations on digital images. This paper employs the digital image processing procedure for microstructure analysis and enhancement of nodular cast iron properties inorder to determine the quality factors. This processing made to sharpen and enhance the microstructure before quantitative analysis. This analysis taken in the analog form of nodular cast iron was performed manually such that, it is time consuming for multiple set of images. To avoid this criteria probably, Digital Image Processing techniques are being used. Often the nodular cast iron images are corrupted or defected during transmission by impulse noise which is often filtered using median filters. In this paper, some of processing steps as pre-processing, segmentation, filtering process and edge detection are done on these images for effective and lossless transmission ensuring the counting of nodules in microstructure and detailed study of grain properties that correlates with the mechanical properties such as ductility, malleability and brittleness. Only 30% restoration of image applicable to an acceptable level is limited. A new filtering method – Resolution Based Median Filter (RBMF) is proposed which achieves more than 95% restoration of nodular cast iron images to an acceptable level. This method optimizes further microstructure analysis of grain smoothening and grain boundary detection using finite element simulation model by varying the intensity level of images. Keywords – Digital Image Processing, Material Microstructure, Edge Detection, Grain Boundary, Resolution Based Median Filter (RBMF).
The document is a project report submitted by four students to fulfill the requirements for a Bachelor of Technology degree in Mechanical Engineering. The report investigates optimizing the wire electrical discharge machining (WEDM) process parameters using Taguchi methods and grey relational analysis. It includes sections on the introduction of WEDM, literature review, work undertaken including the experimental setup and design, results and discussion of optimizing material removal rate, surface roughness and electrode consumption, and conclusions. The goal is to determine the optimal process parameters to achieve higher machining rates with the desired accuracy and minimal surface damage using statistical analysis techniques.
Characterization of Residual Energy Loss and Damage Prediction of wire Rope w...IJERDJOURNAL
ABSTRACT:- The Characterization of residual energy loss of wires extracted from wire rope of type 19x7 immersed in 30% H2SO4 was investigated in this paper. The results obtained from tensile tests on virgin and corroded specimens show a decrease in residual energy as function of immersion hours (8h, 16h, 24h, 32h and 40h). This progressive decrease of energy allowed us to develop a method to calculate damage evolution due to corrosion. Thereafter, and with the establishment of the damage, three stages of damage are distinguished and the value of the critical life fraction is identified, which predict the time of the damage and thus to intervene at the appropriate time before the risk of failure becomes risky.
Modelling of next zen memory cell using low power consuming high speed nano d...eSAT Journals
Abstract Hybrid SET-CMOS circuits which syndicate the assets of both the SET [Single Electron Transistor] and CMOS depicts highest possibilities to be incorporated in practical implementation for future low power VLSI/ULSI configurations. The proposed work is an attempt based on SET-CMOS hybrid circuit to realize the next gen simple Memory Cell. The authors adhered to MIB model for SET and BSIM4 model for CMOS in realizing the complex cell. The maneuver of the proposed circuit is verified subsequently in standard environment. The outcomes are in good trade off with the conventional statistics of existing memory cell. Keywords: SET, SED, Hybrid CMOS-SET, MIB and Memory Cell
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
Optimization of 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.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
This document discusses the design and simulation of a 3D integrated CMOS inverter. It begins with an introduction to 3D integration and its advantages over 2D integration such as shorter interconnects and lower power consumption. It then describes the design process which involves defining process parameters, laying out the inverter, and combining with the process file to generate a 3D model. Simulation results show improvements in parameters like delay, power and chip area compared to previous integration techniques. The conclusion states that 3D integration optimizes these parameters.
IRJET- Estimation of Stress Intensity Factor for the different Crack Mode...IRJET Journal
This document discusses the estimation of stress intensity factors for different crack modes using finite element analysis. It aims to determine the optimal pre-cracked length, crack notch radius, and crack notch angle to eliminate their effects on the stress intensity factor and fracture toughness. A three-dimensional finite element model of compact tension specimens made of stainless steel bonded with epoxy is constructed using ANSYS. The effects of notch angle, notch tip radius, and pre-crack length on the stress intensity factors are studied for different fracture modes. The goal is to find geometries that do not influence the stress intensity factor or fracture toughness.
Analysis of Cold Formed Steel Connections using FEMIRJET Journal
1. The document analyzes cold formed steel connections using finite element modeling (FEM). Four different beam-column connection configurations are modeled and tested, including connections with single or double rows of screws with or without angle plates.
2. Experimental results for each connection are compared to FEM analysis results from ANSYS. The connections are modeled in CATIA and meshed in Hypermesh before analysis in ANSYS to determine load-carrying capacity, displacement, stress, and strain.
3. Preliminary results show that connections using double rows of screws and angle plates have higher load capacities than those with single rows or without plates. Further comparison of experimental and FEM results will provide insight into optimizing cold formed steel
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.
Behaviour Analysis of Corroded Wires Based on Statistical ModelsIJERDJOURNAL
ABSTRACT: Steel wires are the primary components of a lifting wire rope. The behaviour of a wire governs the behaviour of the whole of the cable. The physico-chemical processes like rates of degradation due to the environment (corrosion, etc.) are different for each layer, external layers being more exposed. The analysis of steel wires behaviour is traditionally based on statistical models describing the variability of its properties. For this purpose a statistical study was carried out on two populations of healthy and corroded wires by applying the Student distribution to select the most reliable results and the Weibull distribution to define the survival probability and the failure probability.
The document discusses M20 and M22 connectors that are available in 2.54mm and 2.00mm pitches. These connectors include pin headers, sockets, crimp housings, and variants to meet various application needs. They are suitable for use in consumer electronics, communications equipment, industrial applications, and more. Additional connector options from the manufacturer include fine pitch connectors down to 0.8mm.
IRJET- Investigation of Wire EDM Process Parameters for Machining of Mild...IRJET Journal
This document discusses an investigation of wire electrical discharge machining (WEDM) process parameters for machining mild steel specimens using Taguchi methods. The parameters investigated are pulse-on time, pulse-off time, peak current, and servo voltage. The responses measured are cutting rate, surface roughness, dimensional deviation, and wire wear ratio. Experiments will be conducted on a WEDM machine to determine the optimal process parameters that maximize cutting rate while minimizing surface roughness, dimensional deviation, and wire wear.
1. The document discusses carding, which is the process of untangling fibers and removing impurities to form a web. It defines carding and describes the objectives of carding such as opening fibers, eliminating impurities, and forming slivers.
2. The types of actions that occur in a carding machine are described, including carding action, stripping action, and doffing action. The working principles of revolving flat and roller carding machines are also outlined.
3. Carding is called the "heart of spinning" because it produces slivers of fiber in a more or less uniform state that are suitable for subsequent spinning processes.
This document describes an error compensation technology for straightening linear guide rails based on a wireless sensor network. The technology aims to improve the accuracy of straightening machines by establishing a strain-deflection model and error compensation model using data from wireless strain sensors. An experiment was conducted where strain gauges in a full-bridge circuit configuration measured the strain on a linear guide rail during the straightening process. The feasibility of using the measured strain data and an error compensation scheme to improve the precision of the straightening stroke model was demonstrated.
Analysis of Non Conventional Cross Section of Pipe Made Of Composite MaterialIJMER
Our search for oil is sending us deep into the sea, however this has its own challenges. The salinity of
the sea, acts as an active corrosive agent, and it steadily weakens the structure to get around this, non-corrosive
composite piping has been deployed in critical regions of the structure. However to enable pipe stacking,
sometimes to avail of space constraints, instead of circular c/s, the pipes are increasingly being made of triangular or rectangular c/s. For such c/s theoretical calculations are not possible, hence we need FEA to help us understand the behavior of such c/s.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
Non Linear Finite Element Method of Analysis of Reinforced Concrete Deep BeamIJMER
ABSTRACT: This paper describes analysis of deep beams subjected to two point loading with three different L/D ratios
(1.5, 1.6, 1.71) using Non-linear Finite element method (ANSYS 9.0 software) in order to investigate the stress and strain
distribution pattern at mid-section of the beam. In ANSYS 9.0 software, SOLID 65 and LINK 8 element represent concrete
and reinforcing steel bars. Non-linear material properties were defined for both elements .Using ANSYS software Flexural
Strains and Stresses were determined at mid-section of the beam and shear stresses near the support of the beam. Also the
failure crack-patterns were obtained. Variation of flexural stresses and strains, shear stresses were plotted. It was found that
the smaller the span/depth ratio, the more pronounced is the deviation of strain pattern at mid-section of the beam.
Keywords: Deep Beam, Non-Linear Finite element method, ANSYS 9.0. L/D (Span to depth).
This document summarizes a study that investigated using different tooling materials to reduce distortions in flexible printed circuit boards during a co-curing manufacturing process with carbon fiber structures. Aluminum tooling initially caused curvature along the board's width and stretching along its length due to differences in the materials' thermal expansion coefficients. Switching to steel tooling, which has a lower coefficient, reduced the longitudinal stretching between solder ports as predicted. Aluminum pipe tooling solved the curvature issue but not the stretching. The study shows promise for manufacturing flexible printed circuit boards with carbon fiber composites while maintaining tight tolerances.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
We have excellent business experience and network to undertake the responsibilities
and to work within the requirements and satisfaction of our valued counterparts and
customers in home and abroad.
The document discusses various methods for testing and measuring elements of screw threads, including ISO and BSW threads. It describes how to measure the major diameter, minor diameter, mean diameter, and thread angle of a screw using tools like micrometers, prisms, and an optical comparator. The three-wire method for measuring pitch diameter is also explained in detail, including formulas to calculate measurements based on wire size.
This document outlines challenges facing South African industry and the environment, as well as interventions by the Department of Science and Technology (DST) to address these issues through innovation partnerships and funding programs. It discusses South Africa's technology trade deficit and manufacturing trade deficit as key challenges. The DST interventions described include the Industry Innovation Partnerships Programme, Sector Innovation Funds, and the Environmental Innovation Programme. The Environmental Innovation Programme focuses on developing water and waste innovation through demonstration projects and entrepreneurship. The goals are to improve sustainability, economic competitiveness, and skills in these areas through targeted research, development and innovation.
The document provides a test presentation but does not contain any substantial information to summarize in 3 sentences or less. The title "Test ppt" suggests it may be an empty or placeholder file intended only for testing purposes. No meaningful summary can be generated from the limited information given.
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
Optimization of 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.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
This document discusses the design and simulation of a 3D integrated CMOS inverter. It begins with an introduction to 3D integration and its advantages over 2D integration such as shorter interconnects and lower power consumption. It then describes the design process which involves defining process parameters, laying out the inverter, and combining with the process file to generate a 3D model. Simulation results show improvements in parameters like delay, power and chip area compared to previous integration techniques. The conclusion states that 3D integration optimizes these parameters.
IRJET- Estimation of Stress Intensity Factor for the different Crack Mode...IRJET Journal
This document discusses the estimation of stress intensity factors for different crack modes using finite element analysis. It aims to determine the optimal pre-cracked length, crack notch radius, and crack notch angle to eliminate their effects on the stress intensity factor and fracture toughness. A three-dimensional finite element model of compact tension specimens made of stainless steel bonded with epoxy is constructed using ANSYS. The effects of notch angle, notch tip radius, and pre-crack length on the stress intensity factors are studied for different fracture modes. The goal is to find geometries that do not influence the stress intensity factor or fracture toughness.
Analysis of Cold Formed Steel Connections using FEMIRJET Journal
1. The document analyzes cold formed steel connections using finite element modeling (FEM). Four different beam-column connection configurations are modeled and tested, including connections with single or double rows of screws with or without angle plates.
2. Experimental results for each connection are compared to FEM analysis results from ANSYS. The connections are modeled in CATIA and meshed in Hypermesh before analysis in ANSYS to determine load-carrying capacity, displacement, stress, and strain.
3. Preliminary results show that connections using double rows of screws and angle plates have higher load capacities than those with single rows or without plates. Further comparison of experimental and FEM results will provide insight into optimizing cold formed steel
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.
Behaviour Analysis of Corroded Wires Based on Statistical ModelsIJERDJOURNAL
ABSTRACT: Steel wires are the primary components of a lifting wire rope. The behaviour of a wire governs the behaviour of the whole of the cable. The physico-chemical processes like rates of degradation due to the environment (corrosion, etc.) are different for each layer, external layers being more exposed. The analysis of steel wires behaviour is traditionally based on statistical models describing the variability of its properties. For this purpose a statistical study was carried out on two populations of healthy and corroded wires by applying the Student distribution to select the most reliable results and the Weibull distribution to define the survival probability and the failure probability.
The document discusses M20 and M22 connectors that are available in 2.54mm and 2.00mm pitches. These connectors include pin headers, sockets, crimp housings, and variants to meet various application needs. They are suitable for use in consumer electronics, communications equipment, industrial applications, and more. Additional connector options from the manufacturer include fine pitch connectors down to 0.8mm.
IRJET- Investigation of Wire EDM Process Parameters for Machining of Mild...IRJET Journal
This document discusses an investigation of wire electrical discharge machining (WEDM) process parameters for machining mild steel specimens using Taguchi methods. The parameters investigated are pulse-on time, pulse-off time, peak current, and servo voltage. The responses measured are cutting rate, surface roughness, dimensional deviation, and wire wear ratio. Experiments will be conducted on a WEDM machine to determine the optimal process parameters that maximize cutting rate while minimizing surface roughness, dimensional deviation, and wire wear.
1. The document discusses carding, which is the process of untangling fibers and removing impurities to form a web. It defines carding and describes the objectives of carding such as opening fibers, eliminating impurities, and forming slivers.
2. The types of actions that occur in a carding machine are described, including carding action, stripping action, and doffing action. The working principles of revolving flat and roller carding machines are also outlined.
3. Carding is called the "heart of spinning" because it produces slivers of fiber in a more or less uniform state that are suitable for subsequent spinning processes.
This document describes an error compensation technology for straightening linear guide rails based on a wireless sensor network. The technology aims to improve the accuracy of straightening machines by establishing a strain-deflection model and error compensation model using data from wireless strain sensors. An experiment was conducted where strain gauges in a full-bridge circuit configuration measured the strain on a linear guide rail during the straightening process. The feasibility of using the measured strain data and an error compensation scheme to improve the precision of the straightening stroke model was demonstrated.
Analysis of Non Conventional Cross Section of Pipe Made Of Composite MaterialIJMER
Our search for oil is sending us deep into the sea, however this has its own challenges. The salinity of
the sea, acts as an active corrosive agent, and it steadily weakens the structure to get around this, non-corrosive
composite piping has been deployed in critical regions of the structure. However to enable pipe stacking,
sometimes to avail of space constraints, instead of circular c/s, the pipes are increasingly being made of triangular or rectangular c/s. For such c/s theoretical calculations are not possible, hence we need FEA to help us understand the behavior of such c/s.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
Non Linear Finite Element Method of Analysis of Reinforced Concrete Deep BeamIJMER
ABSTRACT: This paper describes analysis of deep beams subjected to two point loading with three different L/D ratios
(1.5, 1.6, 1.71) using Non-linear Finite element method (ANSYS 9.0 software) in order to investigate the stress and strain
distribution pattern at mid-section of the beam. In ANSYS 9.0 software, SOLID 65 and LINK 8 element represent concrete
and reinforcing steel bars. Non-linear material properties were defined for both elements .Using ANSYS software Flexural
Strains and Stresses were determined at mid-section of the beam and shear stresses near the support of the beam. Also the
failure crack-patterns were obtained. Variation of flexural stresses and strains, shear stresses were plotted. It was found that
the smaller the span/depth ratio, the more pronounced is the deviation of strain pattern at mid-section of the beam.
Keywords: Deep Beam, Non-Linear Finite element method, ANSYS 9.0. L/D (Span to depth).
This document summarizes a study that investigated using different tooling materials to reduce distortions in flexible printed circuit boards during a co-curing manufacturing process with carbon fiber structures. Aluminum tooling initially caused curvature along the board's width and stretching along its length due to differences in the materials' thermal expansion coefficients. Switching to steel tooling, which has a lower coefficient, reduced the longitudinal stretching between solder ports as predicted. Aluminum pipe tooling solved the curvature issue but not the stretching. The study shows promise for manufacturing flexible printed circuit boards with carbon fiber composites while maintaining tight tolerances.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
We have excellent business experience and network to undertake the responsibilities
and to work within the requirements and satisfaction of our valued counterparts and
customers in home and abroad.
The document discusses various methods for testing and measuring elements of screw threads, including ISO and BSW threads. It describes how to measure the major diameter, minor diameter, mean diameter, and thread angle of a screw using tools like micrometers, prisms, and an optical comparator. The three-wire method for measuring pitch diameter is also explained in detail, including formulas to calculate measurements based on wire size.
This document outlines challenges facing South African industry and the environment, as well as interventions by the Department of Science and Technology (DST) to address these issues through innovation partnerships and funding programs. It discusses South Africa's technology trade deficit and manufacturing trade deficit as key challenges. The DST interventions described include the Industry Innovation Partnerships Programme, Sector Innovation Funds, and the Environmental Innovation Programme. The Environmental Innovation Programme focuses on developing water and waste innovation through demonstration projects and entrepreneurship. The goals are to improve sustainability, economic competitiveness, and skills in these areas through targeted research, development and innovation.
The document provides a test presentation but does not contain any substantial information to summarize in 3 sentences or less. The title "Test ppt" suggests it may be an empty or placeholder file intended only for testing purposes. No meaningful summary can be generated from the limited information given.
This document outlines an IP strategy presented by Cordelia Mashau. The vision is to be a world-class innovation agency that enables technological innovation to benefit South Africa's socio-economics. The mission is to deliver socio-economic value through technological innovation across the economy. The presentation discusses different types of intellectual property protection including patents, designs, trademarks, copyright, plant breeders' rights, and trade secrets. It provides advantages and disadvantages of each approach and things to consider when selecting an IP strategy, such as commercialization strategy and target markets.
Coface is a global trade credit insurance provider founded in France in 1946. It has over 60 years of experience in credit risk protection and is present in 66 countries directly and 29 more through partners. Coface protects companies' accounts receivable from unexpected losses through credit insurance that covers domestic and international sales. The insurance provides credit analysis, collection assistance, and allows companies to take on more risk by extending larger credit lines to support sales goals.
The document provides information on Electrical Discharge Machining (EDM). EDM is a manufacturing process where electrical discharges are used to erode material from a workpiece to achieve a desired shape. In EDM, a series of sparks erode material by rapidly recurring electrical discharges between two electrodes separated by a dielectric liquid and subject to an electric voltage. One electrode is the tool that shapes the workpiece. Material removal occurs through thermal melting and vaporization caused by the extreme heat of electrical sparks between the electrodes.
Este documento describe un proyecto para promover la educación virtual en contabilidad utilizando tecnologías de información y comunicación. El proyecto busca generar un entorno de aprendizaje acorde a las demandas del mercado laboral y ayudar a los estudiantes a desarrollar competencias prácticas. También presenta un ejemplo sobre los desafíos que enfrenta una facultad de contaduría al tener profesores desactualizados y propone soluciones como capacitar a los docentes de manera virtual para superar barreras como la distancia ge
Study of process parameter of wire electric discharge machining the reviewIAEME Publication
This document summarizes the process parameters of wire electric discharge machining (WEDM). It discusses the key electrical parameters like pulse duration, pulse interval, servo voltage, and peak current. It also discusses the electrode wire parameters like wire size, material, tension and feed. Additionally, it covers dielectric fluid parameters and workpiece parameters that influence the WEDM process. The document provides details on how each parameter impacts material removal rate and machining characteristics.
IRJET- Analysis on Thread Rolling using Flat DiesIRJET Journal
This document analyzes thread rolling using flat dies. It discusses how thread rolling is a cold forging process that uses reciprocating motion between two flat dies to form threads on a workpiece. An experiment was conducted using aluminum workpieces between 6-16mm in diameter rolled with flat dies on a shaper machine. Loads between 157-200kg were required. Both experimental and analytical results for rolling load, stresses, and power consumption are presented and compared. Finite element analysis in ANSYS was also used to model stresses and deformation during thread rolling with different sized workpieces. The results show thread rolling can effectively form threads on workpieces up to 14mm in diameter using this setup.
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
Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Techniqueijtsrd
The cold work applications like aluminium extrusion, it allows complex shapes to be formed with very smooth surfaces and it is popular for visible architectural applications such as window frames, door frames, roofs, and sign frames should have high toughness, wear resistance, compressive strength, high corrosion resistance, high surface finish and complex profiles. AA 6063 is an aluminium alloy, with magnesium and silicon as the alloying elements. This material can satisfy the above requirements, because of its hardness and strength AA 6063 cannot be machined easily through traditional machining processes. Advanced machining processes are used only when there is no suitable traditional machining process to meet necessary requirements efficiently and economically. Among them wire cut EDM is employed because of its tight tolerances and high surface finish. Based on intense literature survey, it was noticed that very few works were reported on WEDM of AA 6063. As a part of our thesis, WEDM of AA 6063 is considered for the study. In this work Pulse on time, pulse off time, peak current, wire speed, wire tension and flushing pressure of dielectric medium are considered as parameters and their effect on performance measures, metal removal rate MRR and surface roughness will be studied through experimental investigation. Using Taguchi approach, considered parameters will be optimized for maximum MRR and minimum for Surface roughness separately. Taguchi method will be applied to generate mean S N ratios to identify the optimum process parameters. Kandukuri Srinivas | K. Anabayan | P. H. J. Venkatesh "Optimization of Wire Cut EDM of Aluminium Alloy 6063 by using Taguchi Technique" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31047.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/31047/optimization-of-wire-cut-edm-of-aluminium-alloy-6063-by-using-taguchi-technique/kandukuri-srinivas
A Review on Parametric Optimization in Wire Electric Discharge MachiningIJSRD
Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, as it provides an effective solution for producing components made of difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not possible by conventional machining methods. Due to large number of process parameters and responses lots of researchers have attempted to model this process. This paper reviews the research trends in WEDM on relation between different process parameters, include pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, wire speed, wire tension on different process responses include material removal rate (MRR), surface roughness (Ra), sparking gap (Kerf width), wire lag (LAG) and wire wear ration (WWR) and surface integrity factors. Optimization of process parameters is necessary to reduce cost and time of manufacturing. Various optimization and relation finding methods are shown here which are frequently used by researchers. Few conclusions based on existing literature have been extracted from existing literature on optimization of WEDM process parameters.
STUDY OF PROCESS PARAMETER OF WIRE ELECTRIC DISCHARGE MACHINING: THE REVIEWIAEME Publication
Wire EDM is a variation of the Electric Discharge Machining and is commonly known as wire-cut EDM. In WEDM, material is eroded from the work material by a series of discrete sparks
occurring between the work piece and the wire which is generally act as electrode, separated by a stream of dielectric fluid. Dielectric fluid commonly used is deionized water which is act as coolant and flushes the debris away. Work piece is generally electric conductive.
The document provides an overview of the wire drawing process. It discusses how wire drawing works by pulling a wire through progressively smaller dies to reduce its diameter and increase its length. This cold working process improves the material properties of the wire. Key aspects covered include the types of drawing, processing parameters like die design and lubrication, how drawing machines operate using multiple dies, and common die materials like cemented carbides and industrial diamonds.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
DESIGN AND ANALYSIS OF MULTIFACE HYDRAULIC BENDING MACHINE DIEIRJET Journal
This document discusses the design and analysis of a multifaceted hydraulic bending machine die. It begins with an introduction to bending machine operations and describes how existing die designs require multiple dies and more time/space. The proposed new die design would combine multiple bending shapes into a single die to reduce material usage, errors, and improve efficiency. The document then analyzes the proposed die design using finite element analysis software to simulate stresses and strains on sample materials. Results found the new die design reduced stresses on materials compared to existing designs. In conclusion, the bending die process was determined to be important for manufacturing and the new integrated die design improved production over previous methods.
Study of brass wire and cryogenic treated brass wire on titanium alloy using ...eSAT 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
Experimental Investigation to Determine Influence of Process Parameters on Su...IRJET Journal
This document summarizes an experimental investigation into determining the influence of process parameters on surface quality in wire cut electrical discharge machining (WEDM). The study examines the relationship between input process parameters like pulse-on time, pulse-off time, peak current, wire material, and workpiece material, and output variables like surface roughness and electrode wear. Experiments were conducted using an aluminum workpiece material and brass wire electrode. Based on the chosen input parameters and performance measures, a L9 orthogonal array was used to optimize the process parameters for machining aluminum alloys by WEDM.
1. Wire electrical discharge machining (WEDM) is a non-conventional thermo-electric process that removes material from a workpiece using a series of electrical sparks between a wire electrode and the workpiece submerged in dielectric fluid.
2. Many factors influence the WEDM process, including wire positioning, flushing pressure, and material properties. Mathematical models are used to understand relationships between process parameters like peak current and duty factor, and performance measures like material removal rate.
3. Experiments are conducted to determine the effects of process parameters like pulse on/off time and servo voltage on material removal rate and surface roughness when machining H13 hot die steel. The optimal settings are identified using statistical techniques
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
Experimental Analysis on Wire Arc Additive ManufacturingIRJET Journal
The document summarizes an experimental analysis of wire arc additive manufacturing (WAAM) of mild steel. Microscopic analysis found the deposition occurred in both parallel and perpendicular orientations, with grain structures including equiaxed and columnar formations. Hardness testing found values between 18-47 kg/mm2, while mechanical testing found maximum tensile and yield strengths of 25.05 and 560.69 MPa respectively in the through deposition direction. The study aims to optimize the WAAM process by analyzing defects like hot cracking and gas porosity at different deposition parameters.
Advanced Material Process Techniques ExterimentsShivam Patel
1. The document describes three non-conventional machining processes: electrical discharge machining (EDM), abrasive jet machining (AJM), and electro-chemical machining (ECM).
2. EDM works by using electric sparks to erode materials away. AJM uses a high-velocity jet of abrasive particles to erode material. ECM uses electrolysis to dissolve electrode material.
3. Key process parameters for each method like current, gap, and flow rate affect the material removal rate and surface finish. EDM can machine hard materials precisely. AJM is used for drilling, deburring, and other intricate shapes. ECM can stress-free machine various metals.
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
Optimization of Process Parameters for Deep Hole Drilling using Drill EDM for...IRJET Journal
The document discusses optimizing process parameters for deep hole drilling using electric discharge machining (EDM) on tungsten carbide. Experiments were conducted using a copper electrode to drill holes in tungsten carbide. The parameters of discharge current, pulse on time, and pulse off time were optimized using Taguchi methods to maximize machining rate and minimize electrode wear ratio. Grey relation analysis was used to determine a single optimized set of parameters that considers both responses. The optimal parameters found were a discharge current of 6A, pulse on time of 6μs, and pulse off time of 5μs.
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
This document summarizes a study on optimizing electric discharge machining (EDM) parameters to maximize material removal rate (MRR) and minimize electrode wear rate (EWR) when machining stainless steel 316 with a copper electrode. Experiments were conducted using a Taguchi design of experiments with four machining parameters (pulse on time, pulse off time, current, fluid pressure) each at three levels. Results showed that pulse off time and current had the most significant effects on MRR and EWR, respectively. Specifically, MRR increased with longer pulse off times while EWR decreased at higher currents. The optimal settings found were a current of 12 amps and long pulse off time to achieve maximum MRR during EDM of
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.
Similar to Involute Spline Profile Generation using Wire EDM Process (20)
Due to availability of internet and evolution of embedded devices, Internet of things can be useful to contribute in energy domain. The Internet of Things (IoT) will deliver a smarter grid to enable more information and connectivity throughout the infrastructure and to homes. Through the IoT, consumers, manufacturers and utility providers will come across new ways to manage devices and ultimately conserve resources and save money by using smart meters, home gateways, smart plugs and connected appliances. The future smart home, various devices will be able to measure and share their energy consumption, and actively participate in house-wide or building wide energy management systems. This paper discusses the different approaches being taken worldwide to connect the smart grid. Full system solutions can be developed by combining hardware and software to address some of the challenges in building a smarter and more connected smart grid.
A Survey Report on : Security & Challenges in Internet of Thingsijsrd.com
In the era of computing technology, Internet of Things (IoT) devices are now popular in each and every domains like e-governance, e-Health, e-Home, e-Commerce, and e-Trafficking etc. Iot is spreading from small to large applications in all fields like Smart Cities, Smart Grids, Smart Transportation. As on one side IoT provide facilities and services for the society. On the other hand, IoT security is also a crucial issues.IoT security is an area which totally concerned for giving security to connected devices and networks in the IoT .As, IoT is vast area with usability, performance, security, and reliability as a major challenges in it. The growth of the IoT is exponentially increases as driven by market pressures, which proportionally increases the security threats involved in IoT The relationship between the security and billions of devices connecting to the Internet cannot be described with existing mathematical methods. In this paper, we explore the opportunities possible in the IoT with security threats and challenges associated with it.
In today’s emerging world of Internet, each and every thing is supposed to be in connected mode with the help of billions of smart devices. By connecting all the devises used in our day to day life, make our life trouble less and easy. We are incorporated in a world where we are used to have smart phones, smart cars, smart gadgets, smart homes and smart cities. Different institutes and researchers are working for creating a smart world for us but real question which we need to emphasis on is how to make dumb devises talk with uncommon hardware and communication technology. For the same what kind of mechanism to use with various protocols and less human interaction. The purpose is to provide the key area for application of IoT and a platform on which various devices having different mechanism and protocols can communicate with an integrated architecture.
Study on Issues in Managing and Protecting Data of IOTijsrd.com
This paper discusses variety of issues for preserving and managing data produced by IoT. Every second large amount of data are added or updated in the IoT databases across the heterogeneous environment. While managing the data each phase of data processing for IoT data is exigent like storing data, querying, indexing, transaction management and failure handling. We also refer to the problem of data integration and protection as data requires to be fit in single layout and travel securely as they arrive in the pool from diversified sources in different structure. Finally, we confer a standardized pathway to manage and to defend data in consistent manner.
Interactive Technologies for Improving Quality of Education to Build Collabor...ijsrd.com
Today with advancement in Information Communication Technology (ICT) the way the education is being delivered is seeing a paradigm shift from boring classroom lectures to interactive applications such as 2-D and 3-D learning content, animations, live videos, response systems, interactive panels, education games, virtual laboratories and collaborative research (data gathering and analysis) etc. Engineering is emerging with more innovative solutions in the field of education and bringing out their innovative products to improve education delivery. The academic institutes which were once hesitant to use such technology are now looking forward to such innovations. They are adopting the new ways as they are realizing the vast benefits of using such methods and technology. The benefits are better comprehensibility, improved learning efficiency of students, and access to vast knowledge resources, geographical reach, quick feedback, accountability and quality research. This paper focuses on how engineering can leverage the latest technology and build a collaborative learning environment which can then be integrated with the national e-learning grid.
Internet of Things - Paradigm Shift of Future Internet Application for Specia...ijsrd.com
In the world more than 15% people are living with disability that also include children below age of 10 years. Due to lack of independent support services specially abled (handicap) people overly rely on other people for their basic needs, that excludes them from being financially and socially active. The Internet of Things (IoT) can give support system and a better quality of life as well as participation in routine and day to day life. For this purpose, the future solutions for current problems has been introduced in this paper. Daunting challenges have been considered as future research and glimpse of the IoT for specially abled person is given in the paper.
A Study of the Adverse Effects of IoT on Student's Lifeijsrd.com
Internet of things (IoT) is the most powerful invention and if used in the positive direction, internet can prove to be very productive. But, now a days, due to the social networking sites such as Face book, WhatsApp, twitter, hike etc. internet is producing adverse effects on the student life, especially those students studying at college Level. As it is rightly said, something which has some positive effects also has some of the negative effects on the other hand. In this article, we are discussing some adverse effects of IoT on student’s life.
Pedagogy for Effective use of ICT in English Language Learningijsrd.com
The use of information and communications technology (ICT) in education is a relatively new phenomenon and it has been the educational researchers' focus of attention for more than two decades. Educators and researchers examine the challenges of using ICT and think of new ways to integrate ICT into the curriculum. However, there are some barriers for the teachers that prevent them to use ICT in the classroom and develop supporting materials through ICT. The purpose of this study is to examine the high school English teachers’ perceptions of the factors discouraging teachers to use ICT in the classroom.
In recent years usage of private vehicles create urban traffic more and more crowded. As result traffic becomes one of the important problems in big cities in all over the world. Some of the traffic concerns are traffic jam and accidents which have caused a huge waste of time, more fuel consumption and more pollution. Time is very important parameter in routine life. The main problem faced by the people is real time routing. Our solution Virtual Eye will provide the current updates as in the real time scenario of the specific route. This research paper presents smart traffic navigation system, based on Internet of Things, which is featured by low cost, high compatibility, easy to upgrade, to replace traditional traffic management system and the proposed system can improve road traffic tremendously.
Ontological Model of Educational Programs in Computer Science (Bachelor and M...ijsrd.com
In this work there is illustrated an ontological model of educational programs in computer science for bachelor and master degrees in Computer science and for master educational program “Computer science as second competence†by Tempus project PROMIS.
Understanding IoT Management for Smart Refrigeratorijsrd.com
1) The document discusses a proposed design for an intelligent refrigerator that leverages sensor technology and wireless communication to identify food items and order more through an internet connection when supplies are low.
2) Key aspects of the proposal include using RFID to uniquely identify each food item, storing item and usage data in an XML database, monitoring usage patterns to determine reordering needs, and executing orders through an online retailer using stored payment details.
3) Security and privacy concerns with such an internet-connected refrigerator are discussed, such as potential hacking of personal information or unauthorized device control. The proposal aims to minimize human interaction for household management.
DESIGN AND ANALYSIS OF DOUBLE WISHBONE SUSPENSION SYSTEM USING FINITE ELEMENT...ijsrd.com
Double wishbone designs allow the engineer to carefully control the motion of the wheel throughout suspension travel. 3-D model of the Lower Wishbone Arm is prepared by using CAD software for modal and stress analysis. The forces and moments are used as the boundary conditions for finite element model of the wishbone arm. By using these boundary conditions static analysis is carried out. Then making the load as a function of time; quasi-static analysis of the wishbone arm is carried out. A finite element based optimization is used to optimize the design of lower wishbone arm. Topology optimization and material optimization techniques are used to optimize lower wishbone arm design.
A Review: Microwave Energy for materials processingijsrd.com
Microwave energy is a latest largest growing technique for material processing. This paper presents a review of microwave technologies used for material processing and its use for industrial applications. Advantages in using microwave energy for processing material include rapid heating, high heating efficiency, heating uniformity and clean energy. The microwave heating has various characteristics and due to which it has been become popular for heating low temperature applications to high temperature applications. In recent years this novel technique has been successfully utilized for the processing of metallic materials. Many researchers have reported microwave energy for sintering, joining and cladding of metallic materials. The aim of this paper is to show the use of microwave energy not only for non-metallic materials but also the metallic materials. The ability to process metals with microwave could assist in the manufacturing of high performance metal parts desired in many industries, for example in automotive and aeronautical industries.
Web Usage Mining: A Survey on User's Navigation Pattern from Web Logsijsrd.com
With an expontial growth of World Wide Web, there are so many information overloaded and it became hard to find out data according to need. Web usage mining is a part of web mining, which deal with automatic discovery of user navigation pattern from web log. This paper presents an overview of web mining and also provide navigation pattern from classification and clustering algorithm for web usage mining. Web usage mining contain three important task namely data preprocessing, pattern discovery and pattern analysis based on discovered pattern. And also contain the comparative study of web mining techniques.
APPLICATION OF STATCOM to IMPROVED DYNAMIC PERFORMANCE OF POWER SYSTEMijsrd.com
Application of FACTS controller called Static Synchronous Compensator STATCOM to improve the performance of power grid with Wind Farms is investigated .The essential feature of the STATCOM is that it has the ability to absorb or inject fastly the reactive power with power grid . Therefore the voltage regulation of the power grid with STATCOM FACTS device is achieved. Moreover restoring the stability of the power system having wind farm after occurring severe disturbance such as faults or wind farm mechanical power variation is obtained with STATCOM controller . The dynamic model of the power system having wind farm controlled by proposed STATCOM is developed . To validate the powerful of the STATCOM FACTS controller, the studied power system is simulated and subjected to different severe disturbances. The results prove the effectiveness of the proposed STATCOM controller in terms of fast damping the power system oscillations and restoring the power system stability.
Making model of dual axis solar tracking with Maximum Power Point Trackingijsrd.com
Now a days solar harvesting is more popular. As the popularity become higher the material quality and solar tracking methods are more improved. There are several factors affecting the solar system. Major influence on solar cell, intensity of source radiation and storage techniques The materials used in solar cell manufacturing limit the efficiency of solar cell. This makes it particularly difficult to make considerable improvements in the performance of the cell, and hence restricts the efficiency of the overall collection process. Therefore, the most attainable maximum power point tracking method of improving the performance of solar power collection is to increase the mean intensity of radiation received from the source used. The purposed of tracking system controls elevation and orientation angles of solar panels such that the panels always maintain perpendicular to the sunlight. The measured variables of our automatic system were compared with those of a fixed angle PV system. As a result of the experiment, the voltage generated by the proposed tracking system has an overall of about 28.11% more than the fixed angle PV system. There are three major approaches for maximizing power extraction in medium and large scale systems. They are sun tracking, maximum power point (MPP) tracking or both.
A REVIEW PAPER ON PERFORMANCE AND EMISSION TEST OF 4 STROKE DIESEL ENGINE USI...ijsrd.com
This document summarizes a review paper on performance and emission testing of a 4-stroke diesel engine using ethanol-diesel blends at different pressures. The paper reviews several previous studies that tested blends of 5-30% ethanol mixed with diesel fuel. The studies found that a 10-20% ethanol blend can improve brake thermal efficiency compared to pure diesel, while also reducing emissions like NOx and smoke. Higher ethanol blends required advancing the injection timing to allow the engine to run. Ethanol-diesel blends were found to have lower density, viscosity, pour point and higher flash point compared to pure diesel. Overall, ethanol shows potential as a renewable fuel to improve engine performance and reduce emissions when blended with diesel
Study and Review on Various Current Comparatorsijsrd.com
This paper presents study and review on various current comparators. It also describes low voltage current comparator using flipped voltage follower (FVF) to obtain the single supply voltage. This circuit has short propagation delay and occupies a small chip area as compare to other current comparators. The results of this circuit has obtained using PSpice simulator for 0.18 μm CMOS technology and a comparison has been performed with its non FVF counterpart to contrast its effectiveness, simplicity, compactness and low power consumption.
Reducing Silicon Real Estate and Switching Activity Using Low Power Test Patt...ijsrd.com
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Involute Spline Profile Generation using Wire EDM Process
1. IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 08, 2014 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 320
Involute Spline Profile Generation Using Wire EDM Process
Ritesh Anand1
Ashish Singh Solanki2
S. C. Jayswal3
1,2
M. Tech Student
1,2,3
Department of Mechanical Engineering
1,2,3
M.M.M.U.T, Gorakhpur- 273010 (U.P.)
Abstract— Today‟s Mechanical Engineering field is
growing rapidly in designing techniques to manufacture
Splines and Gears. Over the decades, numerous methods
and manufacturing processes have been used in making the
various kinds of Splines based on various criteria, including
applications, reliability, life time, processing time and
manufacturing cost. This work is also carried out with the
same notion of reviewing of manufacturing an External
Involute Spline cutting tool using Wire Electrical Discharge
Machining process and Vertical Milling Machine. Wire
electrical discharge machining (WEDM) is an extremely
accurate type of manufacturing process. This technique was
commercially developed in the 1970s. Spline is a long
flexible strip of metal/plastic/wood used to produce the
curve through the known set of data points. The curved
shape of strip is obtained by pulling it into the transverse
direction using the lead weights or pegs.
Key words: Wire EDM, Involute spline, Involute profile
I. INTRODUCTION
A. Principle of Wire Edm
The principle of wire electrical discharge machine is Spark
Theory. In wire EDM, the conductive materials are
machined with a series of electrical discharges (sparks) that
are produced between an accurately positioned moving wire
(the electrode) and the work piece. High frequency pulses
of alternating or direct current is discharged from the wire
to the work piece with a very small spark gap through an
insulated dielectric fluid (water) [1]. Huge number of sparks
can be observed at one time. This is because actual
discharges occurs more than one hundred times per second,
with discharge sparks lasting in the range of 1/1,000,000
of a second or less than that. The amount of the metal
removed during this small period of spark discharge
depends on the desired cutting speed and the surface finish
required. Fig. 1 shows the schematic diagram of WEDM
machine setup.
B. Working of Wire Edm
In the wire electrode discharge machining, a thin single-
stranded metal wire is fed through the work piece.
Fig. 1 Schematic Diagram of Wire EDM process
This process is similar to contour cutting with a
band saw, a slowly moving wire travels along a prescribed
path, cutting the work piece. This process is used to cut
plates as thick as 300mm and to make punches, tools, and
dies from the hard metals that are too difficult to machine
with other methods. It also creates intricate components for
the electronic industries. The wire, which is constantly
fed from the spool, is held between upper and lower
diamond guides. Guides move in the x-y plane, usually
being CNC controlled and on almost all modern machines
like HS 70a the upper guide can also move independently in
the z-u-v axis, giving rise to the ability to cut tapered and
transitioning shapes and can control axis movements in x-y-
u-v-i-j-k-l-. This gives the wire-cut EDM the ability to be
programmed to cut very intricate and delicate shapes [20].
The wire is controlled by upper and lower diamond guides
that are usually accurate to 0.004mm, and can have a
cutting path or kerf as small as 0.12mm using ø0.1mm
wire, though the average cutting kerf that achieves the best
economic cost and machining time is 0.335mm using
ø0.25mm brass wire. The wire is usually made of brass,
copper, tungsten, or molybdenum and multi-coated wire.
The wire diameter is typically about 0.3mm for roughing
cuts and 0.2mm for finishing cuts. The wire should have
high electrical conductivity and tensile strength, as the
tension on it is typically 60% of its tensile strength. The
wire usually is used only once, as it is relatively
inexpensive compared to the type of operation it performs. It
travels at a constant velocity in the range of 0.15 to 9m/min,
and a constant gap (kerf) is maintained during the cut. The
trend in the use of dielectric fluids is towards clear, low
viscosity fluids. The reason that the cutting width is greater
than the width of the wire is because sparking also occurs
from the sides of the wire to the work piece, causing
erosion. This “overcut” is necessary, predictable, and easily
compensated for. Spools of wire are typically very long.
For example, an 8kg spool of 0.25mm wire is just over 19
kilometers long. Today, the smallest wire diameter is 20
micrometers and the geometry precision is not far from +/-
1 micrometer. The wire- cut process uses water as its
dielectric with the water‟s resistivity and other electrical
properties carefully controlled by filters and de-ionizer
units. The water also serves the very critical purpose of
flushing the cut debris away from the cutting zone. Flushing
is an important determining factor in the maximum feed rate
available in a given material thickness, and poor flushing
situations necessitate the reduction of the feed rate. Along
with tighter tolerances multi-axis EDM wire-cutting
machining center have many added features such as multi-
heads for cutting two parts at the same time, controls for
preventing wire breakage, automatic self-threading features
in case of wire breakage, programmable machining
strategies to optimize the operation.
C. Performance Parameters
1) Cutting Speed:
For Wire EDM, cutting speed is an important
characteristic and it should be as high as possible to give
least machining cycle time. The current cutting speed is
digitally displayed on the machine display screen. The
2. Involute Spline Profile Generation Using Wire EDM Process
(IJSRD/Vol. 2/Issue 08/2014/073)
All rights reserved by www.ijsrd.com 321
machining time “s” is recorded by the Wire EDM machine
time indicator. The cutting speed is measured after the
machining the specimen distance of and recorded. [2]
2) Spark Gap:
Spark gap or overcut is one of the responses which is very
effective in this work. The spark gap is measured in
order to study the correlation between machining
parameters and the spark gap. Spark gap is shown in
Fig. 2. The unit used is m m . Spark gap can be
calculated by the following formula. [2]
..(1)
..(2)
3) Material Removal Rate:
The material removal rate of the work piece is the
volume of the material removed per minute. The
following are equations used to determine material removal
rate (MRR) value.
Fig. 2 Wire EDM cut with spark gap
… (3)
From the material properties, the density of the
machine insert (Solid Carbide) can be known. The mass
of material that was removed by Wire EDM process can be
known by,
… (4)
Therefore, Material Removal Rate (MRR) is measured by,
… (5)
II. INVOLUTE SPLINE
Spline is a long flexible strip of metal/plastic/wood used to
produce the curve through the known set of data points. The
curved shape of strip is obtained by pulling it into the
transverse direction using the lead weights or pegs. The lead
weights or pegs hold the strip in the curved position. The
Spline shape of the strip can be obtained by varying the
number of the lead weights and its positions on the board by
the drafters. The resulting curve appears smooth and fits the
data points. The term Spline curve was originally referred to
a curve drawn in this manner by a drafter. This Spline curve
is a natural cubic Spline possessing C2
continuity. [3]
In modern computer graphics, Splines are preferred
for the following applications:
Design of various types of curves
Design of surface shapes
Digitization of drawings for the computer storage
Specification of the animation paths for the camera
or eyes
Design of aerodynamic efficient automobile bodies
Design of aerospace structures such as surface of
airplanes, rockets etc.
Design of hydrospace structures such as surface of
ship hulls, submarines etc.
Design of curved shape products such as shoes,
bottles etc
Designing of curved involute profile of external
and internal gears.
Now, the question arises, how to generate a Spline
curve on computer? This curve can be mathematically
described with a piecewise cubic polynomial function,
which satisfies C1
(slope) and C2
(slope derivative)
continuities at the boundaries of the curve segments. Thus,
in computer graphics, the Spline curve is a composite curve
formed by joining the polynomials piecewise, satisfying the
specified continuity conditions at the boundary of curved
segments. Splines classification depends on particular type
of polynomials used for drawing the curve with certain
specified boundary conditions. For example, let us analyze
the interpolation of data points shown in Table 1. [3]
X 0 1 2 3 4 5 6
Y 2 1 4 2.75 2 1.5 0
Table 1 Data points for the interpolation [3]
Fig.3 shows the piecewise interpolation of seven
data points using the polynomials of various degrees. For
example, Fig. 1.1a shows the piecewise linear interpolation
of data points. Linear interpolation does not generate smooth
curve. Fig. 8.6b shows the quadratic interpolation of data
points for x < 2; however, for x > 2, curve becomes smooth
because of the fourth degree of polynomial (5 data points).
At x = 2, the curve has corner and derivative of curve is
discontinuous. Only C0
(position) continuity exist at x = 2.
In fig. 1.1c, the interpolation of seven data points is obtained
by considering the sixth degree of polynomial. [3]
(a)
(b)
(c)
Fig. 3 Piecewise Interpolation of Data Points
(a) Linear Interpolation (b) Quadratic Interpolation (c)
Polynomial Interpolation [3]
3. Involute Spline Profile Generation Using Wire EDM Process
(IJSRD/Vol. 2/Issue 08/2014/073)
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Suppose we have to find out a Spline curve to fit
(n+1) control points. The curve fitting for the (n+1) control
points require n curve segments as shown in fig.4. A
parametric cubic Spline given by equation 1.1 has four
coefficients. Thus a total of 4n coefficients are required for
the n curve segments. The main problem with the natural or
drafting Spline is the local control. If any one of the control
point shifts, the entire curve is affected; therefore, does not
allow the local control for the natural Spline curves. The
designer does not prefer the natural cubic Spline because it
is not possible to restructure part of the curve without
affecting the entire curve.
Fig. 4: A piecewise C2
continuous cubic Spline interpolation
of (n+1) control points [3]
Third order cubic polynomial
( ) ... (6)
A. Specification of Spline Curves
There are three methods
On the basis of set of imposed boundary
conditions.
On the basis of matrix that characterizes the
specific spline curve.
On the basis of blending (or basis) functions that
characterizes the spline curve.
These three spline specifications may be illustrated
by assuming the cubic polynomial parametric
representation, for x, y and z, along the spline path in
parameter t as [3]
x(t) = ax.t3
+ bx.t2
+ cx.t + dx
y(t) = ay.t3
+ by.t2
+ cy.t + dy … (7)
z(t) = az.t3
+ bz.t2
+ cz.t + dz
In matrix form, we have
( ) ( ) ( ) =
… (8)
Or P(t) = T.C … (9)
Where „C’ is the polynomial coefficient matrix. For
each polynomial x(t), y(t) and z(t), it is required to calculate
four coefficients a, b, c and d. Therefore, four boundary
conditions are required for the four unknown coefficients.
These constants are evaluated by imposing the sufficient
boundary conditions at the junction of two curve segments.
The boundary conditions may be: [3]
Constraints (positions) at the end points.
Tangents (slopes) at the end points.
Continuity at the junction between the curve
segments.
B. Classification of Spline Curves
Based upon the techniques for the evaluation of four
coefficients a, b, c and d, there are three major
classifications of spline curve:
HERMITE CURVE: Hermite curve is also known
as cubic curve characterized by the two endpoints
and tangent vectors at the endpoints. Hermite curve
passes (interpolate) through the endpoints of the
curve segment and possesses first order (slope)
continuity. [3]
BEZIER CURVE: Two endpoints and two
additional points outside the curve characterize the
Bezier curve. The additional points outside the
curve control the endpoints tangent vectors. Thus,
Bezier curve interpolates the endpoints and
approximates the additional points outside the
curve, i.e., they do not pass through the outside
points. Bezier curves also posses first order (slope)
continuity. [3]
B-SPLINE CURVE: B-Spline curves are
characterized by approximating the endpoints,
allowing first and second order derivatives (C1
and
C2
continuity) to be continuous at the endpoints of
the curve, under certain conditions, the curve may
interpolate the endpoints. [3]
III. EXPERIMENTAL WORK
A. Test Material Specification & Equipment:
By looking at the mechanical and physical properties of the
different materials we chose Aluminum specimen as a test
specimen for testing the Solid Carbide Machine insert with
Involute profile [4].Physical Properties of Aluminum
specimen are tabulated below in Table 2:
Properties Value
Density (g/cc) 2.7
Melting Point (ºC) 582-652
Modulus of Elasticity Tension(GPa) 68.9
Modulus of Elasticity Torsion(GPa) 26
Table 2 Physical properties of Aluminum specimen
Parameters Value
Brinell‟s Hardness 95
Ultimate Tensile Strength (MPa) 310
Tensile Yield Strength (MPa) 276
Modulus of Elasticity (GPa) 68.9
Poisson‟s Ratio 0.33
Fatigue Strength (MPa) 96.5
Machinability 50%
Shear Modulus (GPa) 26
Shear Strength (MPa) 207
Table 3 Mechanical Properties of Aluminum:
The experimental setup of wire EDM machine is
shown in the following fig.. Table 4 has the specifications
of the shown Wire EDM machine.
The NC code is copied into the machine through the
external storage drive. Before setting up the work piece
onto the machine first we need to know the global co-
ordinate system (GCS) of the machine and the co-ordinate
system of the work piece. Then the work piece holder is
fixed to the wire EDM machine rigidly with proper
supports as shown in Fig. 5.
4. Involute Spline Profile Generation Using Wire EDM Process
(IJSRD/Vol. 2/Issue 08/2014/073)
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Fig. 5 Experimental Setup of the Wire EDM Machine
Maximum Work
Piece Height
170mm
Maximum work
piece Weight
100kg
Maximum Table
Feed Rate
600mm/min(Positioning)
300mm/min (Machining)
Wire Diameter
0.1mm, 0.15mm, 0.2mm, 0.25mm,
0.3mm
Wire Feed Rate 40 ~250mm/sec
Wire Tension 3~25N
Water Supply Unit
Capacity
360L
Least Input
Increment
0.0001mm (X, Y, Z, U, V axes),
0.000010 (B-axis)
Least Command
Input
0.001mm
Input Power
Supply
440 10% (50/60Hz 1Hz)
Total Input 13.5KVA
Open Voltage 40V, 50V, 60V, 70V, 85V
Machining Current 30A
Table 4 Wire EDM Machine Specifications
IV. ADVANTAGES AND LIMITATION
A. Advantages of Wire Edm
The process of wire electrical discharge machining (known
as WEDM or wire EDM) offers many advantages which
are unattainable using other methods. Over the last fifteen
years, wire EDM technology has developed into a standard
and popular machining technology. In many operations
formerly performed by conventional manufacturing
processes, the process of wire EDM is regularly less
expensive, infinitely more accurate, and considerably time
saving. Following are some major advantages of wire
electro discharge machining process:
Exotic Metals Capabilities
Complex Geometries
Stacking Plates
Racking of Parts
Raw Materials
Hardness
Burr Free
Flexibility
EDM delivery
B. Limitations of Wire Edm
Following are some major advantages of wire electro
discharge machining process:
Slow Material Removal Rate (MRR).
Reproducing sharp corners on the work piece is
difficult due to electrode wear.
Limited for ferrous alloys but no reaction works in
non-ferrous such as plastic, fiber, wood and so
forth.
Wire EDM machine can only be operated with the
present of electricity.
Unable to interpret technical or manual
data/drawing. Wire EDM machine is enable to
interpret and receiving drawing from such as
CATIA, AutoCAD, Unigraphics, Solid Edge,
Solid Works and etc.
The control system of the electrode may fail to
react quickly enough to prevent the tool and work
piece to get in contact with a consequent short
circuit. It is unwanted because a short circuit
contributes to the removal differently from the
ideal case. The flushing action can be inadequate
to restore the insulating properties of the dielectric
so that the flow of current always happens in the
point of the inter-electrode volume (this is referred
to as arcing), with a consequent unwanted change
of shape (damage) of the tool-electrode and work
piece.
V. APPLICATIONS OF WIRE EDM
Wire EDM has a wide range of applications which are
growing by time day by day. It is extensively used in
automotive, aerospace, molds, tool and die making
industries. Wire EDM also has applicability in the medical,
optical, dental, jewelry industries. The machine‟s ability to
operate unattended for hours or even days further increases
the attractiveness of the process. Accuracy of high value
with intrinsic design and on exotic material has increased its
applicability in medical and R&D areas. Conventional
EDM technique process requires many hours of electrode
fabrication as well as many hours of manual grinding and
polishing. With Wire EDM the overall fabrication time is
reduced by around 37% and the processing time is reduced
by 66%.
Following are the few major applications of wire
EDM process:
Parts with complex geometry
Parts requiring tolerances in the range of tenths
Parts where burrs cannot be tolerated
Delicate parts that are susceptible to tool pressure
Progressive, blanking and trim dies
Extrusion dies
Precious metals
Narrow slots and keyways
Mold components
Tooling for forging or injection molding operations
Medical and dental instrumentation
Cutting hardened materials such as carbide
Cutting difficult to machine materials like hastily,
Inconel and titanium
5. Involute Spline Profile Generation Using Wire EDM Process
(IJSRD/Vol. 2/Issue 08/2014/073)
All rights reserved by www.ijsrd.com 324
Aerospace, defense and electronic parts
Prototypes of different parts
Production parts
VI. RESULTS & CONCLUSION
The Solid carbide Machine inserts are successfully cut in
the Wire EDM machine to get the involute Spline profile.
Total of three inserts were cut on two specimens in Wire
EDM in the process of manufacturing and testing.
Fig. 6: Involute profile cut on Specimen1 (left) and
Specimen2 (right)
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Moulton
[2] Effect of Operational Parameters on performance of
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