The present study analyzed the effects of cold treated brass wire electrode for the machining of hardened high-strength low-alloy (HSLA) steel on wire electric discharge machine. Cold treatment of brass wire at − 70 °C for 24 h has refined its microstructure which results in an increase in electrical conductivity by 24.5%. The experimental work is designed using fractional factorial design to determine the relationship of input variables including servo voltage (SV), pulse on time (T on), pulse off time (T off), wire type (W t), wire tension (T w), and flushing pressure (F p) and response measures including cutting speed (CS), surface roughness (Ra), and kerf width (Kf). In W t , two kinds of brass wires including cold treated (CT) and non-cold treated (NCT) have been used. Empirical models for cutting speed (CS), surface roughness (Ra), and kerf width (Kf) are developed, and their contribution is analyzed through the analysis of variance (ANOVA) technique. Desirability function offers the best combination of input variables to maximize CS and minimize both Ra and Kf simultaneously. T on is observed as the most effective input variable for all response measures, followed by W t and T off. CT brass wire has been observed as the best alternative in multi-objective optimization.
Wire electrical discharge machining (wire EDM), a most common nonconventional machine tool, is extensively employed to produce precise, delicate and intricate profiled shaped parts especially from hard to machine materials. The performance of wire EDM is mainly based on the electrical conductivity of both electrode wires and workpiece materials. The aim of research is to increase cutting speed (CS) of high strength low alloy (HSLA) hardened steel by determining main contributing input process parameters and effect of cold treatment on electrical conductivity of brass wire at -70 °C. Fractional factorial design is used to determine the relationship of CS with input process parameters includes; open voltage, pulse on time, pulse off time, wire tension, flushing pressure of deionized water and brass wires (cold treated -CT, and non-cold treated -NCT). Empirical model for CS is developed based on selected input process parameters and their contribution is analyzed through ANOVA technique. It is learned that pulse on time, pulse off time and wire electrode are the main contributing input process parameters that provide assistance to increase CS of wire EDM. In wire electrodes, cold treated brass wire is observed as a best alternative to enhance machining performance with an increase of electrical conductivity by 24.5 %.
Increasing demand for aluminum matrix composites (AMCs) in the manufacturing sector leads to the development of squeeze casted hybrid AMCs bearing superior mechanical attributes. Excessive hardness due to squeeze pressure and the presence of reinforcement particles makes the machining of AMCs challenging and results in excessive tool wear and inadequate surface finish. Wire electric discharge machining (WEDM) process has been preferred over conventional manufacturing processes for the machining of squeeze casted Al2024/Al2O3/W hybrid composite. This study investigates the selection of the most pertinent wire electrode for the precise machining of Al2024/Al2O3/W. Simple zinc-coated (NT) and cryogenic treated (CT) brass wire electrodes have been selected for machining. Scanning electron microscope (SEM) analysis of CT wire shows that cryogenic treatment enhances the soundness and stability by reducing microcavities in its microstructure. To analyze the effects of cryogenic treatment, the machining performance of CT wire has been compared with NT wire. Besides wire type, the influence of key input variables has also been analyzed on the imperative response measures including cutting speed (CS), surface roughness (SR) and kerf width (KW) to make the machining process more effective. Microstructural analysis of NT wire depicts a high concentration of micro-voids, micro-cracks, and deep craters, while the surface of CT has been observed relatively fine after the machining. Comparative analysis of both wire electrodes has declared that CT wire yields 26.96% and 15.10% superior results for CS and SR respectively, and 6.92% deprived results for KW than NT wire.
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