This document summarizes research on trends in wire electrical discharge machining (WEDM). It reviews several studies that investigated how WEDM process parameters affect outcomes like surface roughness, cutting speed, and material removal rate. Different materials were examined, including metals, composites, and silicon. Process parameters like pulse on-time, current, wire feed rate, and dielectric fluid composition were found to influence the results. Statistical methods like Taguchi experiments and analysis of variance were commonly used to determine significant factors and optimize the process.
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 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.
Investigation on process response and parameters in wire electrical discharge...IAEME Publication
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
Optimization of electrical discharge machiningrakigeo01
This document summarizes a study that used the Taguchi method to optimize the electrical discharge machining (EDM) process for machining tungsten carbide composite. The researchers investigated how EDM process parameters affected material removal rate, electrode wear ratio, and microcrack density on the surface. They conducted experiments using an orthogonal array design from Taguchi methods. Analysis of variance was used to determine the most influential parameters and their optimal levels to maximize material removal rate while minimizing electrode wear ratio and microcrack density.
Anaysis of Material Removal Rate of AISI 304 SS In EDM Processijsrd.com
EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is AISI 304 Stainless steel taking into account its wide usage in industrial applications. In today’s world 304 stainless steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are current, pulse on time and duty cycle. Taguchi method is applied to create an L27 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR), Surface Roughness (SR) and Overcut (OC) is studied and investigated. The tool material is copper. The results obtained showed that current was the most significant parameter followed by pulse on time and the least significant was the duty cycle for the entire three responses namely Material removal rate, Surface roughness and overcut. With the increase in current and duty cycle MRR increased but for pulse on time it increased only up to 100 µs and then started to decrease. SR increased significantly with the increase in current; for pulse on time it increased up to 100 µs and after that there was no significant increase; and in case of duty cycle SR increased up to 70% and then started to decrease. OC increased with the increase in current and pulse on time but in different fashion and in case of duty cycle, OC increased up to 70% and then started decreasing.
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.
Investigation And Optimization Of EDM Process Of AISI 4140 Alloy Steel Using ...IJERA Editor
The purpose of this research work is to determine the optimized settings of key machining factors like pulse on
time, discharge current and duty cycle for AISI 4140 alloy steel using various tool electrodes. The output
responses will be measured are material removal rate (MRR),surface roughness(SR) and tool wear rate(TWR).
Mathematical models are proposed for the above are L27 orthogonal array. The micro structural changes in the
work piece after machining process will also be examined by the use of SEM.
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 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.
Investigation on process response and parameters in wire electrical discharge...IAEME Publication
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
Optimization of electrical discharge machiningrakigeo01
This document summarizes a study that used the Taguchi method to optimize the electrical discharge machining (EDM) process for machining tungsten carbide composite. The researchers investigated how EDM process parameters affected material removal rate, electrode wear ratio, and microcrack density on the surface. They conducted experiments using an orthogonal array design from Taguchi methods. Analysis of variance was used to determine the most influential parameters and their optimal levels to maximize material removal rate while minimizing electrode wear ratio and microcrack density.
Anaysis of Material Removal Rate of AISI 304 SS In EDM Processijsrd.com
EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The work piece material selected in this experiment is AISI 304 Stainless steel taking into account its wide usage in industrial applications. In today’s world 304 stainless steel contributes to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are current, pulse on time and duty cycle. Taguchi method is applied to create an L27 orthogonal array of input variables using the Design of Experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as Material Removal Rate (MRR), Surface Roughness (SR) and Overcut (OC) is studied and investigated. The tool material is copper. The results obtained showed that current was the most significant parameter followed by pulse on time and the least significant was the duty cycle for the entire three responses namely Material removal rate, Surface roughness and overcut. With the increase in current and duty cycle MRR increased but for pulse on time it increased only up to 100 µs and then started to decrease. SR increased significantly with the increase in current; for pulse on time it increased up to 100 µs and after that there was no significant increase; and in case of duty cycle SR increased up to 70% and then started to decrease. OC increased with the increase in current and pulse on time but in different fashion and in case of duty cycle, OC increased up to 70% and then started decreasing.
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.
Investigation And Optimization Of EDM Process Of AISI 4140 Alloy Steel Using ...IJERA Editor
The purpose of this research work is to determine the optimized settings of key machining factors like pulse on
time, discharge current and duty cycle for AISI 4140 alloy steel using various tool electrodes. The output
responses will be measured are material removal rate (MRR),surface roughness(SR) and tool wear rate(TWR).
Mathematical models are proposed for the above are L27 orthogonal array. The micro structural changes in the
work piece after machining process will also be examined by the use of SEM.
Edm drilling of non conducting materials in deionised waterVaralakshmi Kothuru
The document discusses electrical discharge machining (EDM) of non-conductive materials like ceramics in deionized water. Typically, EDM requires a conductive layer on the workpiece, but this layer is difficult to regenerate in water. The study shows that a new conductive layer can be deposited on zirconium dioxide ceramic from the tool electrode during EDM in water. Process parameters are developed that balance material removal with regeneration of this assisting layer. Blind holes up to 1.5 mm deep are successfully drilled in ceramic, demonstrating the feasibility of the approach. Further improvements could enable industrial drilling of cooling holes in ceramic-coated turbine blades using this method.
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
A Review on optimization of Dry Electro Discharge Machining Process Parametersijsrd.com
This document reviews optimization of dry electric discharge machining (EDM) process parameters. It discusses how dry EDM replaces liquid dielectric with gas, improving environmental friendliness. The literature review examines studies on how factors like voltage, current, and gas pressure affect material removal rate, surface roughness, and tool wear rate. Response surface methodology and algorithms like NSGA-II and genetic algorithms have been used to develop models and optimize the conflicting objectives of maximizing material removal rate while minimizing surface roughness. Overall, the document provides an overview of dry EDM optimization research aimed at improving process performance and efficiency.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
This document discusses optimization techniques used in electric discharge machining (EDM). EDM is a non-traditional machining process that uses electrical discharges to erode conductive materials. Key parameters that affect the EDM process include pulse on/off time, voltage, current, discharge energy, electrode polarity, and dielectric fluid. Optimization techniques aim to maximize material removal rate and tool wear ratio while minimizing surface roughness. The document reviews techniques like Taguchi methods, response surface methodology, genetic algorithms, neural networks, and grey relational analysis that have been used to optimize EDM for objectives like material removal rate, surface finish, and tool wear ratio.
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using different electrode materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document provides a review of research on wire electric discharge machining (WEDM). It begins with an abstract that describes WEDM as a process that uses a continuously traveling wire electrode to produce complex shapes in electrically conductive materials by generating sparks between the wire and workpiece. The document then reviews research on WEDM, including studies optimizing process parameters to improve machining performance and productivity and reduce wire breakage. It also discusses the basic principles and cutting process of WEDM, noting that the exact sparking phenomena remains disputed, and lists common wire materials and their applications.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
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.
The detailed study of history features and benefits of wire electric discharg...IAEME Publication
1) The document discusses the history, features, and benefits of wire electric discharge machining (Wire EDM).
2) Wire EDM is a non-traditional machining process that uses electric sparks to erode materials like ceramics, super alloys, and composites that cannot be cut with traditional tools.
3) The process involves an electrically charged wire tool and a workpiece separated by a dielectric fluid. Repeated electric sparks are generated between the wire and workpiece, vaporizing small amounts of material and creating the cut.
Optimization of wedm process parameters using taguchi methodDharam Deo Prasad
This document describes optimizing the parameters of a wire electrical discharge machining (WEDM) process using the Taguchi method and grey-based Taguchi method. It introduces WEDM and its components/process. Key parameters investigated are pulse-on time, pulse-off time, wire feed, and gap voltage. Experiments are conducted using Taguchi's orthogonal array design and the grey-based Taguchi method is applied to optimize the parameters for maximizing material removal rate and minimizing surface roughness and kerf width. Confirmation experiments show improved machining efficiency with the optimized parameters.
An overview of experimental investigation of near dry electrical discharge ma...iaemedu
This document provides an overview of experimental investigations into near-dry electrical discharge machining (EDM). Near-dry EDM uses a mixture of gas and small amount of dielectric liquid, making it more environmentally friendly than conventional wet EDM which uses large amounts of dielectric fluid. Near-dry EDM was found to have higher material removal rates than wet EDM at lower discharge energies and better surface finish quality than dry EDM. Several studies investigated the effects of EDM process parameters like discharge current, gap voltage, and pulse on time on material removal rate and surface roughness. However, more work is needed to optimize parameters to make near-dry EDM more cost-effective. The document reviews the limited existing studies on near
Comparative study on variation of process characteristics on al and die steel...IAEME Publication
This document presents the results of an experimental study on the influence of electrical discharge machining (EDM) parameters on process characteristics when machining aluminum (Al) and die steel components. Specifically, it examines the effect of changing current on material removal rate, tool wear ratio, and surface roughness for the two materials. The results showed that increasing current from 10A to 20A led to higher material removal rates and tool wear ratios for both Al and die steel. It also resulted in increased surface roughness parameters (average roughness, average maximum height, maximum roughness depth) for the machined surfaces of both materials. The findings provide information on selecting optimal current parameters to achieve desired EDM efficiency and surface finish when machining Al and die steel
This document discusses various methods for improving material removal rate (MRR) in electrical discharge machining (EDM). It explains that EDM uses thermoelectric energy from electric sparks to remove material from conductive workpieces. MRR can be improved through electrode design and geometry, controlling process parameters like voltage, current, and pulse duration, using EDM variations with ultrasonic vibration or rotation, mixing powders into the dielectric fluid, using gas as the dielectric medium, and techniques like multi-spark EDM. Overall, MRR is an important performance measure that relies on empirical methods and requires further research due to the complex interrelationship between electrical and non-electrical parameters in the stochastic EDM process.
This document presents a seminar report on dry and near dry electrical discharge machining (EDM). EDM uses electric sparks to erode material away from a conductive workpiece. Dry EDM replaces the liquid dielectric fluid with gas, which avoids issues with liquid fluids but causes lower material removal rates and tool overheating. Near dry EDM uses a liquid-gas mixture as the dielectric to improve material removal rates over dry EDM while avoiding debris deposition issues of wet EDM. The document discusses the EDM process, developments in dry and near dry EDM, their applications in prototype production and broken tool removal, and concludes that near dry EDM improves performance issues of dry EDM.
This document summarizes research on using powder mixed dielectrics in electrical discharge machining (PMEDM). It first reviews the basic material removal mechanism in EDM and important process parameters. It then discusses various dielectric categories used in EDM, including hydrocarbon oils, deionized water, and their advantages/disadvantages. The main body of the document provides a detailed review of using powder mixed with dielectric in PMEDM, focusing on how powder affects spark characteristics and machining performance based on powder material, size, and concentration. It concludes with a discussion of research trends, gaps, and challenges in industrializing PMEDM technology.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
Effect Of Wire Edm Process Parameters On Surface Roughness Of Aisi-4140 (Carb...dbpublications
WEDM is used for cutting intricate or complicated shapes which are not possible with conventional machining methods. Wire cut EDM is a cutting process used widely where conventional machining processes are not useful. A metal wire with a Dielectric medium travels through a path and perform machining procedure .The main objective of the present work is to investigate the effects of various WEDM process parameters on the machining quality and to obtain the optimal sets of process parameters like Pulse-ON time, Pulse-OFF time, current, wire feed are studied by conducting an experiment. Taguchi Method is to design the experiment. L16 orthogonal array is used to conduct the experiment. An AISI-4140 (carbon steel) is used as a work piece material in the form of square bar. The surface roughness (SR) is selected as response variable.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
A Periodical Production Plan for Uncertain Orders in a Closed-Loop Supply Cha...IJERA Editor
This document proposes fuzzy set theory models to address production planning under uncertain demand in a closed-loop supply chain system. Specifically, it develops a Fuzzy Chance-Constrained Production Mix Model (FCCPMM) that uses fuzzy set concepts like possibility distributions and α-cut sets to formulate constraints allowing the decision maker to account for demand uncertainty in an optimization model seeking to maximize profit. The model is demonstrated through a numerical example and is intended to help producers better cope with production risks from uncertain customer orders in a closed-loop supply chain context.
291 ( space solar power satellite system) (1)sanjiivambati59
Solar power satellites have been proposed as a way to collect solar energy in space and transmit it to receivers on Earth. In 1968, Dr. Peter Glaser introduced the concept of using large solar panels in geosynchronous orbit to convert sunlight to microwaves and beam the energy back to rectennas on Earth. NASA and the Department of Energy studied the feasibility in the 1970s. In 1999, NASA initiated the Space Solar Power Exploratory Research and Technology program to further design studies. While solar power satellites could provide a continuous source of clean energy without pollution, many technical challenges remain regarding construction, power transmission levels, and thermal management that require more research and development.
Edm drilling of non conducting materials in deionised waterVaralakshmi Kothuru
The document discusses electrical discharge machining (EDM) of non-conductive materials like ceramics in deionized water. Typically, EDM requires a conductive layer on the workpiece, but this layer is difficult to regenerate in water. The study shows that a new conductive layer can be deposited on zirconium dioxide ceramic from the tool electrode during EDM in water. Process parameters are developed that balance material removal with regeneration of this assisting layer. Blind holes up to 1.5 mm deep are successfully drilled in ceramic, demonstrating the feasibility of the approach. Further improvements could enable industrial drilling of cooling holes in ceramic-coated turbine blades using this method.
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
A Review on optimization of Dry Electro Discharge Machining Process Parametersijsrd.com
This document reviews optimization of dry electric discharge machining (EDM) process parameters. It discusses how dry EDM replaces liquid dielectric with gas, improving environmental friendliness. The literature review examines studies on how factors like voltage, current, and gas pressure affect material removal rate, surface roughness, and tool wear rate. Response surface methodology and algorithms like NSGA-II and genetic algorithms have been used to develop models and optimize the conflicting objectives of maximizing material removal rate while minimizing surface roughness. Overall, the document provides an overview of dry EDM optimization research aimed at improving process performance and efficiency.
Latest Research Trend of optimization Techniques in Electric Discharge Machin...sushil Choudhary
This document discusses optimization techniques used in electric discharge machining (EDM). EDM is a non-traditional machining process that uses electrical discharges to erode conductive materials. Key parameters that affect the EDM process include pulse on/off time, voltage, current, discharge energy, electrode polarity, and dielectric fluid. Optimization techniques aim to maximize material removal rate and tool wear ratio while minimizing surface roughness. The document reviews techniques like Taguchi methods, response surface methodology, genetic algorithms, neural networks, and grey relational analysis that have been used to optimize EDM for objectives like material removal rate, surface finish, and tool wear ratio.
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using different electrode materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document provides a review of research on wire electric discharge machining (WEDM). It begins with an abstract that describes WEDM as a process that uses a continuously traveling wire electrode to produce complex shapes in electrically conductive materials by generating sparks between the wire and workpiece. The document then reviews research on WEDM, including studies optimizing process parameters to improve machining performance and productivity and reduce wire breakage. It also discusses the basic principles and cutting process of WEDM, noting that the exact sparking phenomena remains disputed, and lists common wire materials and their applications.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
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.
The detailed study of history features and benefits of wire electric discharg...IAEME Publication
1) The document discusses the history, features, and benefits of wire electric discharge machining (Wire EDM).
2) Wire EDM is a non-traditional machining process that uses electric sparks to erode materials like ceramics, super alloys, and composites that cannot be cut with traditional tools.
3) The process involves an electrically charged wire tool and a workpiece separated by a dielectric fluid. Repeated electric sparks are generated between the wire and workpiece, vaporizing small amounts of material and creating the cut.
Optimization of wedm process parameters using taguchi methodDharam Deo Prasad
This document describes optimizing the parameters of a wire electrical discharge machining (WEDM) process using the Taguchi method and grey-based Taguchi method. It introduces WEDM and its components/process. Key parameters investigated are pulse-on time, pulse-off time, wire feed, and gap voltage. Experiments are conducted using Taguchi's orthogonal array design and the grey-based Taguchi method is applied to optimize the parameters for maximizing material removal rate and minimizing surface roughness and kerf width. Confirmation experiments show improved machining efficiency with the optimized parameters.
An overview of experimental investigation of near dry electrical discharge ma...iaemedu
This document provides an overview of experimental investigations into near-dry electrical discharge machining (EDM). Near-dry EDM uses a mixture of gas and small amount of dielectric liquid, making it more environmentally friendly than conventional wet EDM which uses large amounts of dielectric fluid. Near-dry EDM was found to have higher material removal rates than wet EDM at lower discharge energies and better surface finish quality than dry EDM. Several studies investigated the effects of EDM process parameters like discharge current, gap voltage, and pulse on time on material removal rate and surface roughness. However, more work is needed to optimize parameters to make near-dry EDM more cost-effective. The document reviews the limited existing studies on near
Comparative study on variation of process characteristics on al and die steel...IAEME Publication
This document presents the results of an experimental study on the influence of electrical discharge machining (EDM) parameters on process characteristics when machining aluminum (Al) and die steel components. Specifically, it examines the effect of changing current on material removal rate, tool wear ratio, and surface roughness for the two materials. The results showed that increasing current from 10A to 20A led to higher material removal rates and tool wear ratios for both Al and die steel. It also resulted in increased surface roughness parameters (average roughness, average maximum height, maximum roughness depth) for the machined surfaces of both materials. The findings provide information on selecting optimal current parameters to achieve desired EDM efficiency and surface finish when machining Al and die steel
This document discusses various methods for improving material removal rate (MRR) in electrical discharge machining (EDM). It explains that EDM uses thermoelectric energy from electric sparks to remove material from conductive workpieces. MRR can be improved through electrode design and geometry, controlling process parameters like voltage, current, and pulse duration, using EDM variations with ultrasonic vibration or rotation, mixing powders into the dielectric fluid, using gas as the dielectric medium, and techniques like multi-spark EDM. Overall, MRR is an important performance measure that relies on empirical methods and requires further research due to the complex interrelationship between electrical and non-electrical parameters in the stochastic EDM process.
This document presents a seminar report on dry and near dry electrical discharge machining (EDM). EDM uses electric sparks to erode material away from a conductive workpiece. Dry EDM replaces the liquid dielectric fluid with gas, which avoids issues with liquid fluids but causes lower material removal rates and tool overheating. Near dry EDM uses a liquid-gas mixture as the dielectric to improve material removal rates over dry EDM while avoiding debris deposition issues of wet EDM. The document discusses the EDM process, developments in dry and near dry EDM, their applications in prototype production and broken tool removal, and concludes that near dry EDM improves performance issues of dry EDM.
This document summarizes research on using powder mixed dielectrics in electrical discharge machining (PMEDM). It first reviews the basic material removal mechanism in EDM and important process parameters. It then discusses various dielectric categories used in EDM, including hydrocarbon oils, deionized water, and their advantages/disadvantages. The main body of the document provides a detailed review of using powder mixed with dielectric in PMEDM, focusing on how powder affects spark characteristics and machining performance based on powder material, size, and concentration. It concludes with a discussion of research trends, gaps, and challenges in industrializing PMEDM technology.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
Effect Of Wire Edm Process Parameters On Surface Roughness Of Aisi-4140 (Carb...dbpublications
WEDM is used for cutting intricate or complicated shapes which are not possible with conventional machining methods. Wire cut EDM is a cutting process used widely where conventional machining processes are not useful. A metal wire with a Dielectric medium travels through a path and perform machining procedure .The main objective of the present work is to investigate the effects of various WEDM process parameters on the machining quality and to obtain the optimal sets of process parameters like Pulse-ON time, Pulse-OFF time, current, wire feed are studied by conducting an experiment. Taguchi Method is to design the experiment. L16 orthogonal array is used to conduct the experiment. An AISI-4140 (carbon steel) is used as a work piece material in the form of square bar. The surface roughness (SR) is selected as response variable.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
A Periodical Production Plan for Uncertain Orders in a Closed-Loop Supply Cha...IJERA Editor
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The Opportunity of Using Wind to Generate Power as a Renewable Energy:"Case o...IJERA Editor
The demand ofsustainable energy is increased daily by expanding our cities and creating new cities and suburbswith huge towers besides increasing in population,moreover the environment and human life is threatening by the pollutions resulted from energy generation. For this reason the researchersattracted todevelop renewable energy and explore its large benefits and unit capacity. Wind power is one of the clean renewable energy resources.Therefore the importance of implementing this resource in Kuwait draws our attention to make this research to emphasis on the technical and economic aspects due to acceptable environmental conditions. Whereas, in some areas of the world, such as in Japan, has some geographical and electrical restrictions such as power fluctuating for land wind generation. And the introductionof large amount of wind power generation tends to be extremely difficult and even impossible in some location. This research is aimed to concentrate on the visibility of utilizing the wind energy as complementary source for the existing steam and gas turbine power stations in Kuwait, furthermore point out the economical perspectives that will guide us to take the right decision. The location of wind farms is very important in this aspect where we cannot build such projects inside the cities between buildings besides meeting the minimum requirements for economic generation. The study prove to us that even at a location which is almost close to the inhabitants buildings ( Kuwait airport ) can get accepted results the historical data was collected from the weather station at internet. The implementation of wind turbine farms is foreseen to be economic in generation for long run and encouragestepping up toward putting the infrastructure design. Furthermoreit is an opportunity for creating new job vacancies.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
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.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document describes a study that used Response Surface Methodology (RSM) to optimize the Wire Electric Discharge Machining (WEDM) process for D-2 tool steel. RSM and a central composite design were used to develop models for how the material removal rate (MRR) responds to four machining parameters: pulse on time, pulse off time, peak current, and servo voltage. 30 experiments were conducted according to the design. The results showed that MRR increases with pulse on time and peak current, but decreases with pulse off time and servo voltage.
Investigation on process response and parameters in wire electricalIAEME Publication
This document summarizes a study that investigated the effects of process parameters on wire electrical discharge machining (WEDM) of Inconel 625. The study used Taguchi's design of experiments methodology to determine the optimal levels of six machining parameters (pulse-on time, pulse-off time, wire feed, upper flush, lower flush, wire tension) for minimizing kerf width, electrode wire wear, and maximizing surface hardness. Twenty-five experiments were conducted according to an L25 orthogonal array. Regression analysis was used to establish relationships between the process parameters and responses. The results showed good agreement between experimental and predicted values, demonstrating the methodology can determine optimal machining conditions for WEDM of Inconel
Investigation on process response and parameters in wire electricaliaemedu
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document summarizes a seminar presentation on optimizing process variables for wire-cut electric discharge machining of the super alloy Udimet-L605. The presentation covers literature reviewing previous research on EDM of various alloys, characteristics of Udimet-L605, the experimental design using Taguchi methods, response parameters of material removal rate and surface roughness, and modeling the process using support vector machine algorithms. The conclusion is that Taguchi methods were used to optimize for single and multi-objectives, and further investigation of process variable influence on responses will be conducted.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Gray Relational Basedanalysis of Tool SteelIRJET Journal
This document presents research on optimizing the electro discharge machining (EDM) process for tool steel using Taguchi methods and grey relational analysis. The researchers conducted experiments with tool steel as the workpiece material and copper as the electrode. Response variables included material removal rate (MRR) and surface roughness (Ra). Taguchi methods were used to design the experiments and orthogonal arrays. Grey relational analysis was then used to analyze the multiple responses and determine the optimal process parameters. The analysis involved normalizing the experimental data, calculating grey relational coefficients and grades, and analyzing the results using ANOVA to select parameters that maximize MRR and minimize Ra.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9µs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13µs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1µin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
This document describes a framework developed using Taguchi methods to optimize two quality characteristics, surface roughness and angular accuracy, in wire electrical discharge machining (W-EDM) operations. An experiment was conducted using an L9 orthogonal array to investigate the effects of four controllable factors (pulse on time, feed rate, voltage, and wire tension), each at three levels, on the two response variables. The optimal settings identified were able to improve both surface roughness and angular accuracy, as confirmed through additional validation experiments. This research established a systematic approach for obtaining a single optimal parameter setting to maximize multiple quality characteristics simultaneously in machining applications.
IRJET- Advance Manufacturing Processes Review Part IV: Electrical Dischar...IRJET Journal
1) Electrical discharge machining (EDM) is a non-traditional machining process that uses electric sparks to erode conductive materials.
2) EDM can machine hard materials like steel and super alloys regardless of their hardness by melting and vaporizing small amounts of material with each electric spark.
3) The document reviews research on EDM process parameters and their effects on material removal rate, surface roughness, and tool wear. It also summarizes recent research trends in EDM like ultrasonic vibration-assisted EDM and EDM in water.
This document discusses analyzing process parameters in wire electrical discharge machining (WEDM) of Inconel 718, a nickel-based super alloy. The objectives are to investigate significant WEDM parameters that affect material removal rate, electrode wear ratio, and hardness; study the effect of parameters on dimensional output like circularity and cylindricity; establish optimal WEDM parameters for Inconel; and develop an empirical model using Taguchi's design of experiments. The document reviews literature on modeling and optimizing WEDM performance and discusses the mechanism and influencing parameters of the WEDM process.
Process Parameter Optimization of WEDM for AISI M2 & AISI H13 by Anova & Anal...IJERA Editor
The document summarizes a study on optimizing process parameters for wire electrical discharge machining (WEDM) of AISI M2 and AISI H13 steel alloys. Experiments were conducted using a Taguchi L16 orthogonal array with peak current, pulse on time, pulse off time, and workpiece material as parameters. Responses measured included material removal rate, surface roughness, kerf width, and spark gap. ANOVA showed peak current and pulse on time most significantly affected responses. For AISI M2, low peak current, short pulse on and off times minimized surface roughness and kerf width while maximizing material removal rate. For AISI H13, low peak current, long pulse on time
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Trends in Wire Electrical Discharge Machining (WEDM): A Review
1. Ms. Sharanya S. Nair Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 12( Part 1), December 2014, pp.71-76
www.ijera.com 71 | P a g e
Trends in Wire Electrical Discharge Machining (WEDM): A
Review
Ms. Sharanya S. Nair*, Ms. Nehal Joshi**
*Department of Mechanical Engineering, Gujarat Technological University, India
** Department of Mechanical Engineering, Gujarat Technological University, India
ABSTRACT
The exponential growth of manufacturing industries and production and the increased need of accuracy and
precision throws the spotlight on the nontraditional machining processes. The machining of metals and non-
metals having special properties like high strength, high hardness and toughness is done by non- conventional
machining methods. Wire electrical discharge machining is one of the earliest non-traditional machining
processes. This machining process competes with conventional machining such as milling, broaching, grinding
etc. However, its ability to cut extremely intricate and delicate shapes with utmost accuracy makes this process
most suitable among all other processes. The otherwise hard to be machined materials like carbides, tungsten,
zirconium etc. can be easily machined using this process. This paper reviews notable work done in the field of
WEDM by various researchers.
Keywords - cutting speed, kerf width, material removal rate (MRR), parametric optimization, surface roughness
(Ra), and wire electrical discharge machining (WEDM)
I. INTRODUCTION
Wire electrical discharge machining is a
nontraditional widely accepted machining process
used in tool & die industry, aerospace, surgical,
automotive, nuclear industries because of its
capability to cut materials having intricate profiles,
very hard materials which are difficult to cut by
conventional machining process. The wire electrical
discharge machining is similar to that of electrical
discharge machining (EDM) process, in which there
is no contact between tool and work piece. Because
of the invention of Wire electrical discharge
machining (WEDM) process, it evolved as best
machining process for producing complicate parts
with very good surface finish and dimensional
accuracy.
II. WEDM PROCESS
Wire electrical discharge machining (EDM) is a
non-traditional machining process that uses
electricity to cut any conductive material precisely
and accurately with a thin, electrically charged
copper or brass wire as an electrode. During the wire
EDM process, the wire carries one side of an
electrical charge and the workpiece carries the other
side of the charge.
Fig: 1 Schematic diagram of WEDM process
When the wire gets close to the part, the
attraction of electrical charges creates a controlled
spark, melting and vaporizing microscopic particles
of material. The spark also removes a miniscule
chunk of the wire, so after the wire travels through
the workpiece one time, the machine discards the
used wire and automatically advances new wire. The
process takes place quickly—hundreds of thousands
of sparks per second—but the wire never touches the
workpiece. Wire EDM machines use a dielectric
solution of deionized water to continuously cool and
flush the machining area while EDM is taking place.
In many cases the entire part is submerged in the
dielectric fluid, while high-pressure upper and lower
flushing nozzles clear out microscopic debris from
the surrounding area of the wire during the cutting
process. The fluid also acts as a non-conductive
RESEARCH ARTICLE OPEN ACCESS
2. Ms. Sharanya S. Nair Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 12( Part 1), December 2014, pp.71-76
www.ijera.com 72 | P a g e
barrier, preventing the formation of electrically
conductive channels in the machining area. When the
wire gets close to the part, the intensity of the electric
field overcomes the barrier and dielectric breakdown
occurs, allowing current to flow between the wire and
the workpiece, resulting in an electrical spark.
III. REVIEW OF WEDM RESEARCH
WORK
This section presents the various notable
research trends carried out in the field of WEDM.
Anmol Bhatia, Sanjay Kumar and Praveen
Kumar [1] dealt with the optimization of surface
roughness (SR) while machining High Carbon High
Chromium steel on wire electrical discharge machine
using Brass wire. Based on Taguchi Single Response
optimization technique, the values of input
parameters like peak current, pulse on time, pulse off
time, wire tension were set such that the surface
roughness obtained was minimum. After the
experiments, it was found that surface roughness was
affected maximum by pulse off time. The observed
results were also validated using confirmation
experiments. It was observed that the error between
the experimental and predicted values for SR was
3.93%.
Shivkant Tilekar, Sankha Shuvra Das and P.K
Patowari [2] investigated the effect of process
parameters on surface roughness and kerf width of
aluminum and mild steel using single response
optimization technique. For experimentation, spark
on time, spark off time, input current and wire feed
rate were used as input parameters while many other
parameters were taken as fixed parameters. By
ANOVA method, the spark on time and input current
were observed to have statistically significant effect
on surface roughness of aluminum and mild steel
respectively. In case of kerf width, wire feed rate and
spark on time had maximum influence on aluminum
and mild steel respectively.
Brajesh Kumar Lodhi and Sanjay Agarwal [3]
have attempted to optimize the machining conditions
for surface roughness(SR) in WEDM of AISI D3
steel based on (L9 Orthogonal Array) Taguchi
methodology. The effect of various machining
parameter such as pulse-on time, pulse- off time,
peak current and wire feed had been studied. It was
identified that the pulse on time and current had
influenced more than the other parameters considered
in this study. The confirmation experiment had been
conducted. Result showed that the errors associated
with SR were only 3.042 %.
G. Selvakumar, G.Sornalatha et al[4] carried out
experimental analysis for the selection of the most
optimal machining parameter combination for wire
electrical discharge machining (WEDM) of 5083
aluminum alloy based on the Taguchi experimental
design (L9 orthogonal array) method. A series of
experiments were performed by considering pulse-on
time, pulse-off time, peak current and wire tension as
input parameters while surface roughness (Ra) and
cutting speed (CS) were considered responses. The
optimal machining parameters setting for the
maximum cutting speed and minimum surface
roughness were found using Taguchi methodology.
Then, additive model was employed for prediction of
all (34
) possible machining combinations. The
process was optimized by Pareto-optimality approach
and a technology table was proposed for optimum
machining 5083 Al alloy. ANOVA revealed that the
CS was independent on wire tension and Ra was
independent on pulse-off time and wire tension. An
optimum parameter combination for the minimum Ra
and the maximum CS was obtained by the analysis of
signal-to- noise (S/N) ratio.
R. Bagherian Azhiri & R. Teimouri et al [5]
presented experimental study of dry WEDM of
Al/SiC metal matrix composite where the liquid
dielectric is replaced with gaseous medium to
enhance the machining environment safety. Oxygen
gas and brass wire were selected through a series of
experiments as they guaranteed superior cutting
velocity. The effect of pulse on time, pulse off time,
gap voltage, discharge current, wire tension and wire
feed were studied on cutting velocity(CV) and
surface roughness(SR) using Taguchi’s orthogonal
array. Relationship between process inputs and
responses were correlated using, adaptive neuro-
fuzzy inference system. At the end, a grey relational
analysis had been used to maximize CV and
minimize SR simultaneously. Also according to
ANOVA, pulse on time and current were found to
have significant effect on CV and SR.
Ashish Srivastava , Amit Rai Dixit et al [6]
presented an experimental study on composite of
Al2024 reinforced with SiC to investigate the effects
of wire electric discharge machining(WEDM) for
three levels of each parameters such as current ,pulse
on time and reinforcement percentage on surface
finish and Material Removal Rate(MRR). Response
surface methodology (RSM) technique had been
applied to optimize the machining parameters for
minimum surface roughness and maximum MRR.
The reinforcement percentages of SiC were taken as
2%, 4% and 6%. From the Scanning Electron
Microscopy (SEM) images of machined samples it
was observed that the surface finish that a non-
conventional machining process gave was better than
the surface finish we got from the conventional
machining process. Results of experiments showed
3. Ms. Sharanya S. Nair Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 12( Part 1), December 2014, pp.71-76
www.ijera.com 73 | P a g e
that surface roughness increased with the increase in
pulse on time, peak current and reinforcement
percentage while MRR increased with the increase in
pulse on time, peak current and decreased with the
increase in reinforcement percentage.
Adeel Ikram, Nadeem Ahmad Mufti et al [7]
reported the effect and optimization of eight control
factors on three response measures namely material
removal rate (MRR), surface roughness and kerf
using Taguchi’s L18 orthogonal array. The
workpiece used was tool steel D2. The control factors
used were wire feed velocity, dielectric pressure,
pulse on-time, pulse off-time, open voltage, wire
tension and servo voltage by varying the material
thickness. Analysis of variance (ANOVA) and
signal-to- noise (S/N) ratio were used as statistical
analyses to identify the significant control factors and
to achieve optimum levels respectively. Additionally,
linear regression and additive models were developed
for surface roughness, kerf and material removal rate
(MRR). Results of the confirmatory experiments
were found to be in good agreement with those
predicted. It had been found that pulse on-time is the
most significant factor affecting the surface
roughness, kerf and material removal rate.
Ravindranadh Bobbili, V. Madhu, and A. K Gogia
et al [8] presented the influence of machining
parameters on surface roughness (SR) and material
removal rate (MRR) of high strength armor steel
using wire cut electrical discharge machining
(WEDM). Six different process parameters used in
the experiment were: pulse-on time, pulse-off time,
wire feed, flushing pressure, spark voltage, and wire
tension. Taguchi’s technique had been employed for
experimental investigation. Results show that pulse-
on time, pulse-off time, and spark voltage are
significant variables to MRR and surface roughness
(SR). By employing ANOVA optimum process
parameter combinations for better MRR and SR were
achieved. This technique is cost effective and time
saving in evaluating the machining parameters
without conducting large number of experiments.
Relation between the process parameters and
response characteristics was established by
eventually developing mathematical models using
regression analysis.
Kannachi Kanlayasiri and Prajak Jattakul et al
[9] determined an optimal cutting condition of
dimensional accuracy and surface roughness for
finishing cut of wire- EDMed K460 tool steel. Box-
Behnken design was used as the experimental
strategy while multi response optimization was
performed using the desirability function. The
process variables investigated in this experiment
included cutting speed, offset distance and peak
current. According to the results, peak current and
offset distance had significant effect on the
dimension of the specimen and only the peak current
affects the surface roughness. The optimization of the
process variables on the dimension and surface
roughness was simultaneously performed to find an
optimal cutting condition. Using the optimal cutting
condition, the dimension and the surface roughness
of the cut specimens were still within the specified
limits.
Farnaz Nourbakhsh, K. P. Rajurkar et al [10]
presented an experimental investigation of wire
electro-discharge machining (WEDM) of titanium
alloy. The influence of zinc-coated brass wire on the
performance of WEDM was compared with high-
speed brass. The effect of seven process parameters
including pulse width, servo reference voltage, pulse
current, and wire tension was investigated on process
performance parameters such as cutting speed, wire
rupture and surface integrity. A Taguchi L18 design
of experiment (DOE) has been applied. Results
showed that the cutting speed increases with peak
current and pulse interval. Surface roughness was
found to increase with pulse width and decrease with
pulse interval. The Analysis of Variance (ANOVA)
also indicated that voltage, injection pressure, wire
feed rate and wire tension have non-significant effect
on the cutting speed. Compared with high-speed
brass wire, zinc-coated brass wire resulted in higher
cutting speed and smoother surface finish. Also, SEM
photographs proved that uncoated wire produces a
surface finish with more cracks, craters and melted
drops. However, High speed brass wire resistance
against wire rupture in tough conditions, high pulse
width and low time between two pulses, is much
more than zinc coated wire since tensile strength
(130,000 PSI) of zinc coated wire is less than the
high speed brass wire tensile strength. Scanning
Electron Microscopic (SEM) examination of
machined surfaces was performed to understand the
effect of different wires on work piece material
surface characteristics.
Uday A. Dabade [11] discussed the multi-objective
optimization using Taguchi based GRA to improve
the surface integrity on turned surface of Al/SiCp
MMCs. Surface quality/integrity related parameters
such as cutting forces, surface roughness, residual
stresses and micro- hardness variation were selected
as target responses. The optimum process parameters
to improve the surface integrity on Al/SiCp
composites were identified. Experiments on Al/SiCp
composites of four different compositions are
performed using L27 orthogonal array as per the
Taguchi method. The GRA based best and worst
machining conditions change with size and volume
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fraction of reinforcement in composites. The best
optimized combination of machining conditions to
enhance the surface quality/integrity on machined
surfaces of Al/SiCp composite is use of 0.8 mm tool
nose radius, wiper type insert geometry, 0.05 mm
rev-1 feed rate, 40 m min-1 cutting speed and 0.2 mm
depth of cut.
Chin-Chang Yeh & Kun-Ling Wu et al [12]
implemented wire electrical discharge machining
(WEDM) to process polycrystalline silicon ingot, and
the influences on surface characteristics were
examined. At first, two different dielectrics, pure
water and pure water with sodium pyrophosphate
powder, were experimented to compare their effects
on cutting speed and surface roughness. In the
experiment, pure water with sodium pyrophosphate
powder had shown that it could enhance process
efficiency and improve surface smoothness. From the
preliminary experimental results, it could be found
that the cutting speed of the phosphorous dielectric is
1.48 times faster than pure water. Phosphorous
dielectric under high temperature would bring about
the electrolysis effect. This reduces the surface
roughness 12 % compared with pure water. The
phosphorous dielectric could also effectively reduce
the kerf loss. Then, the effects on cutting efficiency
with different concentrations were examined. After
setting the concentration, several experiments were
conducted to find out how different currents and
pulse-on times affect the cutting efficiency and
surface roughness. The findings in this study prove
that using phosphorous dielectric on WEDM could be
applied onto polycrystalline silicon cutting. In
addition, pure water with sodium pyrophosphate
powder increases both working efficiency and
improves infiltration of the phosphorous element on
the surface. Based on the results, this study could be
a future reference for industry and academic
researchers on the solar cell process.
V.K. Saini, Zahid A. Khan et al [13] presented the
investigation and optimization of WEDM parameters
using Taguchi method. A set of experiments was
undertaken to find the effects of various WEDM
process parameters on surface roughness. Three
process parameters chosen were Pulse on-time (Ton),
Pulse off time (Toff) and Discharge current (or pulse
current). The experiments were carried out as per
design of experiments approach using L9 orthogonal
array. Signal to Noise (S/N) ratios of the Surface
Roughness (SR) for all experiments were calculated.
The experimental results revealed that pulse on-time
of 5 µs, pulse off-time of 3 µs and discharge current
of 2A yielded the optimal i.e. minimum surface
roughness. The level of importance of the machining
parameters & their individual contributions on the
surface roughness is determined by using ANOVA.
Results showed that Pulse on-time (Ton) with a
contribution of 48.38% had the greatest effect on the
machining output characteristics. Parameter A i.e.
Discharge current with a 45.38% share was the next
most significant influence on the output parameters,
followed by Parameter C i.e. machine’s Pulse off-
time, (Toff) 5.5%. Surface roughness at the best
combination was 2.331 µm.
Kapil Kumar & Sanjay Agarwal et al [14]
attempted to optimize the machining conditions for
maximum material removal rate and maximum
surface finish based on multi-objective genetic
algorithm. Experiments, based on Taguchi’s
parameter design, were carried out to study the effect
of various parameters, viz. pulse peak current, pulse-
on time, pulse-off time, wire feed, wire tension and
flushing pressure, on the material removal rate and
surface finish. The workpiece used was made of
high-speed steel (M2, SKH9) and zinc coated copper
wire was used as wire electrode. It had been observed
that a combination of factors for optimization of each
performance measure was different. So, mathematical
models were developed between machining
parameters and responses like metal removal rate and
surface finish by using nonlinear regression analysis.
These mathematical models were then optimized by
using multi-objective optimization technique based
on Non-dominated Sorting Genetic Algorithm-II to
obtain a Pareto-optimal solution set. The results of
optimization indicated that the material removal rate
and surface finish was influenced more by pulse peak
current, pulse duration, pulse-off period and wire
feed than by flushing pressure and wire tension.
Results also indicated that the surface quality
decreases as the MRR increases and they varied
almost linearly. Out of 50 optimal solutions, the best
parametric combination that yielded the highest
possible MRR, while maintaining the specified
surface finish requirement, i.e. 3.69 μm, were: pulse
peak current030 A, pulse duration037 μs, pulse-off
time050 μs, wire feed07 m/min, wire tension01260 g,
flushing pressure02.1 kg/cm2.
Pragya Shandilya & P.K.Jain et al [15] optimized
the process parameters during machining of
SiCp/6061 Al metal matrix composite (MMC) by
wire electrical discharge machining (WEDM) using
response surface methodology (RSM). Four input
process parameters of WEDM (namely servo voltage
(V), pulse-on time (TON), pulse-off time (TOFF) and
wire feed rate (WF)) were chosen as variables to
study the process performance in terms of cutting
width (kerf). In addition mathematical models were
also developed for response parameter. Properties of
the machined surface had been examined by the
scanning electron microscopic (SEM). Input process
parameters had been found to play a significant role
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ISSN : 2248-9622, Vol. 4, Issue 12( Part 1), December 2014, pp.71-76
www.ijera.com 75 | P a g e
in the minimization of kerf. ANOVA results showed
that voltage and wire feed rate were highly
significant parameters and pulse-off time was less
significant. Pulse-on time had insignificant effect on
kerf. For targeted value of kerf the optimized values
of servo voltage was 70.06 V, pulse-on time was 2.81
micro seconds, pulse-off time was 7.79 micro
seconds and wire feed rate was 8.90 m/min. SEM
images of the cut surfaces revealed that the fine
surface finish was obtained when machining was
done at a combination of lower levels of input
process parameters. When machining was done at
combination of higher levels of input process
parameters, craters and black patches raised on the
machined surface.
Sateesh Kumar Reddy K & Ramesh S et al [16]
carried out parametric optimization of Wire electrical
discharge machining of Composite material
(Al+3%SiC) . They attempt to find the best affecting
parameters for maximize material removal rate
(MRR) and minimizing surface roughness (Ra). The
Design of Experiment (DOE) and Analysis was
conducted in Taguchi Method. The selected
parameters to determine the larger MRR and smaller
Ra were Voltage (A), Pulse on (B), Pulse off (C) and
Current (D). The influence of parameters and
optimization is performed using Taguchi Method and
ANOVA was conducted with the help of General
linear Method in Mini Tab 16 software respectively
.The parameters like Voltage and Pulse off mostly
affected on MRR .The increase in Voltage and Pulse
off caused the MRR to increase and decreases
respectively. The parameters like Pulse on and
Voltage mostly affected Ra. The increase in Pulse on
and Voltage caused the Ra to increase respectively.
The error between the Taguchi analysis and Anova
analysis was very minute for MRR and Ra that were
0.00 and 1.23 respectively. The hardness, Ra and
MRR of material was increased when workpiece was
machined using DM water as dielectric fluid. The
hardness, Ra and MRR decreased when workpiece
was machined using air as dielectric fluid.
Aniza Aliasa, Bulan Abdullaha et al [17]
investigated the influence of feed rate on the
performance of WEDM on Titanium Ti-Al-4V. Brass
wire was employed as the electrode in this study. An
attempt was made to determine the important
machining parameters for performance of WEDM
viz. Kerf width, MRR and Ra. The best combination
of machining parameter viz. machine feed rate (4
mm/min), wire speed (8 m/min), wire tension (1.4kg)
and voltage (60V) were identified. The main goal
was to obtain the maximum MRR with the minimum
kerf and surface roughness in setting the machining
parameters. Machine feed rate has been found to
play an important role in this experimental work. In
finding how the output parameter varies with the
variation in the input parameter, three set of
experiments as shown in Table 1 have been studied.
All experiments were performed in constant current
(4A) mode.
IV. CONCLUSION
From all the literature review, Wire cut EDM has
resulted as the most efficient and accuracy machining
process. The Wire cut EDM machining process can
machine any material irrespective of their hardness
and they can produce any intricate shape.
WEDM is a well-established non- conventional
material removal process capable of meeting the
diverse machining requirements posed by the
demanding metal cutting industries. The main
objective of the WEDM process is to obtain the
optimal parameters without making compromise with
its performance measures. It has been commonly
applied for the machining and micro-machining of
parts with intricate shapes and varying hardness
requiring high profile accuracy and tight dimensional
tolerances. However the main disadvantage of the
process is the relatively low machining speed, as
compared to the other non- traditional machining
processes such as the laser- cutting process, largely
due to its thermal machining technique. Choosing
optimal parametric conditions is vital for successful
running of WEDM. The major input parameters of
WEDM are pulse on time, pulse off time, peak
current, gap voltage, wire feed, wire tension etc. and
the response parameters are material removal rate
(MRR), surface roughness, cutting speed, surface
integrity, dimensional deviation etc. In the modern
era of science and technology, the requirement of
accurate and precise engineering products is
successfully fulfilled by the wire electrical discharge
machining (WEDM) process.
V. ACKOWLEDGEMENT
I would like to acknowledge and extend my
sincere gratitude to Ms. Nehal Joshi for the constant
support, valuable advice and help that she provided
for preparing this paper.
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