Abstract Mathematical modeling / Simulation is a process of designing a model of a real system and conducting experiments with it for the purpose of understanding the behavior of the system. It is widely used for analyzing mechanisms also. Investigations of the various stages of mechanism design like synthesis and analysis using mathematical model is an effective tool by high development of computing technique, which enables complicated problems to be solved with minimum number of assumptions. Four bar mechanisms are widely used in automobiles and industrial applications. The present work aims at developing a computational environment for synthesizing and analyzing the mechanism both kinematically and kinetically. This work presents a simple and good mathematical model for getting the relevant parameters like link lengths, their velocities, their accelerations and the forces acting on it with the input of output function. The computational environment for the model is developed using a ‘Ch’ language, an embeddable C/C++ interpreter. The effect of varying parameters like link lengths, output functions on displacement, velocity, acceleration and forces has been studied.
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).
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.
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).
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.
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.
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.
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).
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.
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.
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.
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).
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.
Inversion of Mechanisms: Theory of Machines With VideosNaseel Ibnu Azeez
Theory Of machines. Detailed demonstration of Inversion of Four bar mechanism, slider crank mechanism and Double slider crank mechanism.
contact me at naseel@live.com
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.
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
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
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.
EDM machining is used for very hard and complex cutting of conducting materials with
higher surface finish and close dimensions. EDM process parameters are affected by both electrical
and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on
electro discharge machine with copper as cutting tool electrode. This paper presents the effect of
control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge
Machine. In this paper both the electrical factors and non electrical factors has been focused which
governs MRR and EWR. Paper is based on Design of experiment and optimization of EDM process
parameters. The technique used is Taguchi technique which is a statistical decision making tool helps
in minimizing the number of experiments and the error associated with it. The research showed that
the Pulse off time, Current has significant effect on material removal rate and electrode wear rate
respectively
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.
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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)
All rights reserved by www.ijsrd.com 322
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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[4] T.N.T. Goodman, D.S. Meek, D.J. Walton,
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[19]Dhanik, S., Joshi, S.S., Ramakrishnan, N. and Apte,
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