In this paper, wire electrical discharge machining of D3 tool steel is studied. Influence of pulse-on time, pulse-off time, peak current and wire speed are investigated for MRR, dimensional deviation, gap current and machining time, during intricate machining of D3 tool steel. Taguchi method is used for single characteristics optimization and to optimize all four process parameters simultaneously, Grey relational analysis (GRA) is employed along with Taguchi method. Through GRA, grey relational grade is used as a performance index to determine the optimal setting of process parameters for multiobjective characteristics. Analysis of variance (ANOVA) shows that the peak current is the most significant parameters affecting on multi-objective characteristics. Confirmatory results, proves the potential of GRA to optimize process parameters successfully for multi-objective characteristics.Keywords ANOVA Á D3 tool steel Á Grey relational analysis Á Multi-objective optimization Á Taguchi method Á Wire electrical discharge machining (WEDM)
Achieving the desired mechanical properties in thin wall ductile iron castings poured in industrial production foundries is a challenge. In this work, the effect of copper addition (up to 0?74%) and melt processing (Ba based stream inoculation) on the matrix structure, mechanical properties and fracture behaviour of ductile iron castings with varying section thickness (4-16 mm) were investigated in a regular jobbing foundry. It was possible to obtain 80% pearlitic structure without carbides in 4 mm sections, giving a tensile strength of 658 MPa with 2?5% ductility and 264 Brinell hardness. The solidification behaviour represented by the cooling curves helped in checking the effectiveness of the melt treatment by observing the amount of undercooling. Fractography studies of tensile specimens showed the change in fracture mechanisms due to increase in copper content on fracture paths. The increased amount of pearlite in the matrix exhibited brittle fracture with river pattern.
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