Analysis and optimization of wire Electro-Discharge Machining process parameters for the efficient cutting of Aluminum 5454 alloy

Wasif, Muhammad; Khan, Yasir Ahmed; Zulqarnain, Ali; Iqbal, Syed Amir

doi:10.1016/j.aej.2021.11.048

Cited by 10 publications

(3 citation statements)

References 21 publications

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“…RSM is used to create statistical equations that precisely represent the connection between input variables and output. Usually, these equations are generated according to equation (1).…”

Section: Response Surface Methodologymentioning

confidence: 99%

“…Wire Electro Discharge machine (WEDM) is one of the better options in non-traditional machining processes for machining of Nickel based alloys because it removes material based on an electro-thermal principle to machine any hard material or irregular shapes and sharp corners accurately and precisely. This made WEDM get acceptance from many industries like automotive, nuclear, and aerospace for making turbine blades,biomedical and electronic industries, etc, Its precision in obtaining high dimensional accuracy made it useful in diemaking and prototype parts [1]. WEDM is an electric-erosion process where a series of sparks occur around more than lakh per second between the wire electrode and workpiece.…”

Section: Introductionmentioning

confidence: 99%

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Experimental study on wire electric discharge machining of nimonic 90 using coated electrode

Khan,

2024

Eng. Res. Express

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WEDM machine is an unconventional machine that got accepted in the industries because of its skill to machine any material precisely in the required shape and size. Wire electric discharge machine uses electrical energy to cut hard conductive materials. In the present study, Nimonic 90 a nickel-based superalloy is machined in WEDM using a zinc-coated brass wire electrode to study its surface characteristics and its machinability. Experiments were carried out with central composite design with controllable WEDM factors such as Pulse duration, Servo-voltage, and wire-tension were used to investigate machining performance such as material transfer rate (MRR) and average surface roughness (Ra).The second order quadratic models are developed between WEDM parameters and responses by regression analysis. Analysis of Variance was employed to validate the accuracy of the established statistical models and the impact of the process variables. The RSM based optimization was used to find the optimal process parameter of Wire Tension 11.962 N, Pulse on Time 79.785 µs and Servo Voltage 100 V to achieve maximum MRR of 5.3574 (mm3/min) and minimal Ra of 2.6513 (μm). The validity of the optimized values are verified by conducting confirmation experiments and found that errors are within the permissible limit. Further, the surface morphology of the WEDMed specimen was carried out through SEM to ascertain the mechanisms of material removal under the different settings of WEDM.

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“…RSM is used to create statistical equations that precisely represent the connection between input variables and output. Usually, these equations are generated according to equation (1).…”

Section: Response Surface Methodologymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Experimental study on wire electric discharge machining of nimonic 90 using coated electrode

Khan,

2024

Eng. Res. Express

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“…[20][21][22]. EDM can produce craters in any conducting material by using thermal energy, irrespective of the hardness of the material [23][24][25][26]. This causes less tool wear than conventional manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization of machining parameters of Ti-6Al-2Sn-4Zr-2Mo alloy using EDM process through grey relational analysis

Perumal¹,

Rajkumar²,

Venkatesan

et al. 2023

Eng. Res. Express

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Due to its high corrosion resistance and low density, it is tedious to machine high strength materials such as titanium alloy for the manufacture of engineering products related to aerospace, automobiles, and medical applications. In this study, an attempt was made to consider the impact of tool electrodes in the electrical discharge machining method for successful machinability of titanium alloy. High temperatures are used during electrical discharge machining to melt and vaporise the hard titanium alloy. In the current work, an EDM machining method was used to machine a Ti-6Al-2Sn-4Zr-2Mo alloy while using the input parameters of pulse on time, voltage, and current as process parameters. The experiments were carried out based on the workpiece, and surface morphology was performed on the workpiece surface. The process parameters were optimised using the Multi-Response Grey Relation Analysis method, and a major effects plot was created to see how the factors affected the MRR and surface roughness. Surface finish and MRR have been discovered to be directly correlated with discharge current. These are the best process parameters for machining pulse on time (150 s), voltage (60 V), and discharge current (16 A).

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Optimization of WEDM Process Parameters Using Grey-Taguchi Approach for the Development of Turning Tool Insert

Kumar,

Mondal

2023

Lecture Notes in Mechanical Engineering

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Analysis and optimization of wire Electro-Discharge Machining process parameters for the efficient cutting of Aluminum 5454 alloy

Cited by 10 publications

References 21 publications

Experimental study on wire electric discharge machining of nimonic 90 using coated electrode

Experimental study on wire electric discharge machining of nimonic 90 using coated electrode

Multi-response optimization of machining parameters of Ti-6Al-2Sn-4Zr-2Mo alloy using EDM process through grey relational analysis

Optimization of WEDM Process Parameters Using Grey-Taguchi Approach for the Development of Turning Tool Insert

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