Analysis and Optimization of Process Parameters in Wire Electrical Discharge Machining Based on RSM: A Case Study

Sağbaş, Aysun

doi:10.5772/intechopen.107539

Response Surface Methodology - Research Advances and Applications 2023

DOI: 10.5772/intechopen.107539

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Analysis and Optimization of Process Parameters in Wire Electrical Discharge Machining Based on RSM: A Case Study

Aysun Sağbaş¹

Abstract: In this book chapter a review and critical analysis on current research trends in wire electrical discharge machining (WEDM) and relation between different process parameters including 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, wire lag and wire wear ration (WWR) and surface integrity factors was investigated. On the basis of critical evaluati… Show more

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Cited by 3 publications

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Corner cutting accuracy for thin-walled CFRPC parts using HS-WEDM

AbouHawa,

Eissa

2024

Discov Appl Sci

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Carbon Fiber-Reinforced polymer (CFRP) composite parts with thin-walled corners are in great demand in aircraft, cars, and precision instruments. Nonetheless, the fabrication of these parts is difficult due to their low stiffness. High-speed WEDM is an advanced technique for cutting thin CFRP components as it is a non-contact method for removing materials. Nonetheless, testing results demonstrate an unavoidable deformation in the thin-walled corners of the CFRP composite. The objective of this study is to improve the accuracy of corners in thin-walled CFRP composite parts. The research utilized a Taguchi L16 orthogonal array to investigate the influence of various process parameters, including pulse-on duration (Pon), pulse-off duration (Poff), and input current (I), as well as the parameter CFRP plate thickness (T), on corner inaccuracy. The CFRP thickness varied between 0.5, 1.0, 1.5, and 2.0 mm, and the corner angles examined were 30°, 60°, 90°, and 120°. Additionally, a second-order polynomial regression model was used to determine the correlation between the process parameters and corner inaccuracy at various corner angles. Also, a multi-response optimization technique using a composite desirability coupled with a generalized reduced gradient were used to find the optimal process combination across various CFRP thicknesses. According to the research findings, the most relevant process parameters impacting corner accuracy at different angles were the pulse-on duration and input current. To achieve accurate corners with different angles, the optimal process parameters were identified: Pon (40µs), Poff (15µs), and I (4A) for CFRP thicknesses 0.5 and 1.0mm, and Pon (45μs), Poff (30μs), and I (2A) for thicknesses 1.5 and 2.0mm.

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Corner cutting accuracy for thin-walled CFRPC parts using HS-WEDM

AbouHawa,

Eissa

2024

Discov Appl Sci

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Machinability and pulse characteristics of Ti-16Al-14Nb (α/β) alloy in wire-electric discharge machining process: A surface integrity study

Veera Venkata Nagaraju,

Joseph Davidson,

Venkatesh

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part E:

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The goal of the present work is to produce the efficient cutting of Ti-16Al-14Nb (α/β) alloy through wire-electric discharge machining and contemplate the terminologies such as machining ability, surface integrity and material removing capability. For this, the experimentation has been designed by considering three process parameters, pulse-on time ( Ton), pulse-off time ( Toff) and peak current ( Ip) at three significant levels (low, high, intermediate) in L27 order designed from design of experiments. The effect of these process variables on pulse characteristics, surface roughness ( Ra), kerfwidth ( Kw) and material removal rate ( MRR) is analyzed and mathematically modeled with analysis of variance. The results state that the highest MRR (0.521, 0.51, 0.506 mm3/sec) and low surface roughness (8.91, 8.89, 8.68 µm) values are observed at the highest level (110 µs, 15 µs, 8 A). If the pulse duration is kept at low ( Ton = 40µs, Toff = 3µs), the increase in peak current from 3 A to 8 A leads to a 64.54% increase in MRR and a 52.9% increase in Ra values. ANOVA results stated that Ton has contributed 20.4%, 35.8% and 19.3%, and Ip has contributed 43.1%, 30.5% and 46.6% influence on MRR, Kw and Ra respectively. The voltage–current characteristics studies confirmed that the strong intense pulses at a higher peak current (8 A) resulted in the increased MRR (0.521 mm3/sec) and Ra (8.43 µm) leading to the formation of swages and ridges. The surface integrity analysis derived from Abbott–Firestone curve agreed that the lowest level has shown better skewness ( Rsk = −0.274) and at highest level showed a larger deviation in skewness ( Rsk = +2.672) signifies that higher asymmetry (poor) of the surface.

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Effects of High Level of Lead (II) Oxide (PbO) Usage on Accumulator and Response Surface Method

PIÇAKÇI,

YALÇIN

2023

Black Sea Journal of Engineering and Science

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This study involved the preparation of lead oxide paste for use in the production of lead-acid batteries. The paste was applied to the positive plates, and its performance effects were tested on the battery. Morphological and surface area analyses were conducted using SEM and BET, respectively, after the performance tests. Two mixtures of lead oxide ratios, 25%Pb-75%PbO (sample A) and 30% Pb-70% PbO (sample B), were used. The dough was applied to positive grids and passed through the curing process. SEM images revealed that tribasic sulfate (3BS) structures had a higher charge acceptance rate than tetrabasic sulfate (4BS) structures. BET analyses showed that the surface area of the samples with A ratio was higher than that of B. Electrical tests were conducted in the laboratory, and the A sample was found to be 12% more effective in the first charging efficiency than the B sample. Sample A was also found to be 67% more efficient in charge acceptance tests and 6.5% more efficient in cycle tests. The study also showed that increasing the %Pb ratio in the product decreases the initial charge efficiency, charge acceptance, and cycle life. Finally, the response surface method was used to examine the 2D picture of the relationship between lead percentage and yield, and it was found that the highest yield was obtained at 26% lead yield, with the yield being inversely proportional to the increase in lead percentage, likely due to the effect of particle size and surface area.

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Analysis and Optimization of Process Parameters in Wire Electrical Discharge Machining Based on RSM: A Case Study

Cited by 3 publications

References 57 publications

Corner cutting accuracy for thin-walled CFRPC parts using HS-WEDM

Corner cutting accuracy for thin-walled CFRPC parts using HS-WEDM

Machinability and pulse characteristics of Ti-16Al-14Nb (α/β) alloy in wire-electric discharge machining process: A surface integrity study

Effects of High Level of Lead (II) Oxide (PbO) Usage on Accumulator and Response Surface Method

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