Empirical modeling and optimization of kerf and wire wear ratio in wire electrical discharge machining

Prasad, D. V. S. S. S. V.; Krishna, A. Murali

doi:10.1007/s00170-014-6445-8

Cited by 33 publications

(14 citation statements)

References 17 publications

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“…High T off means less spark time to produce discharge energy for the removal of workpiece material. For this reason, narrower Kf is produced [67]. In the case of W t , Kf seems to be increased when shifted from NCT wire to CT wire (Fig.…”

Section: Kerf Widthmentioning

confidence: 92%

“…The reason behind this phenomenon is that increased T on causes discharge energy more intense which ultimately results in a powerful explosion due to which more material is removed and deeper craters formed on the machined surface. For this reason, larger Kf with poor surface finish is produced [67]. On the other hand, Kf decreases with an increase in T off shown in Fig.…”

Section: Kerf Widthmentioning

confidence: 94%

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Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel

Tahir

Jahanzaib

2019

J Braz. Soc. Mech. Sci. Eng.

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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.

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Section: Kerf Widthmentioning

confidence: 92%

Section: Kerf Widthmentioning

confidence: 94%

Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel

Tahir

Jahanzaib

2019

J Braz. Soc. Mech. Sci. Eng.

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“…They have assigned the weight in a random manner to the response variables. Prasad and Krishna [21] divided the problem as (a) optimization of kerf width with wire wear as a constraint and (b) optimization of wire wear with kerf width as a constraint. They arrived at the optimal parameters by applying harmony search algorithm-based optimization.…”

Section: Review Of Past Research Workmentioning

confidence: 99%

Modeling and desirability approach-based multi-response optimization of WEDM parameters in machining of aluminum metal matrix composite

Kumar

Manna

Kumar

2018

J Braz. Soc. Mech. Sci. Eng.

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The study presents machining aspects of particulate silicon carbide reinforced aluminium metal matrix composite (Al/ SiC p-MMC) using wire-cut electric discharge machining process. The influences of process parameters such as pulse on time, pulse off time, spark gap voltage, peak current, wire tension and wire feed rate on response variables such as workpiece cutting speed, surface roughness (R a) and spark gap have been investigated. The Box-Behnken's design has been utilized to plan the experiments, and response surface methodology is employed for developing quadratic regression models for selected response variables. Desirability function approach has been used to solve the multi-response optimization problem by assigning the weightages to the selected responses as per the user's requirement of quality or productivity. The study recommends optimal process conditions such as pulse on time 0.75 ls, pulse off time 16 ls, spark gap voltage 35 V, peak current 120 A, wire tension 1200 g, and wire feed rate 10 m/min for effective machining of Al/ SiC p-MMC, which has been validated by conducting confirmation experiments. The developed regression models for selected responses revealed compatible results, thereby justifying their acceptability.

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“…Zhang et al [95] attempted to predict optimal process parameter combination for achieving better surface integrity using back propagation neural network combined with genetic algorithm (BPNN-GA) and Non-dominated Sorting Genetic Algorithm-II [87]. Prasad and Gopala Krishna [96] described the benefit of using harmony search algorithm for achieving minimum kerf and wire wear ratio. Pramanik et al [81] proposed a hypothesis by using grey relational analysis to predict optimum process parameter combination to achieve higher machining speed and better surface finish while machining boron carbide material.…”

Section: Modelling and Simulation Techniquesmentioning

confidence: 99%

A progress review in wire electrical discharge machining process

Balan¹,

Giridharan²

2017

Int. J. Automot. Mech. Eng.

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Wire Electrical Discharge Machining (WEDM) is an electrothermal non-traditional machining process used for machining electrically conductive materials that are difficult to machine. Material removal in WEDM is by means of spark erosion. WEDM is proven to be the alternative for producing complex parts with higher degree of dimensional accuracy and better surface finish. Over the years, a significant amount of research was globally carried out to explore the WEDM process capability. This paper aims to explore the research work carried on parametric influence of WEDM process variables on various output performance measures. The paper also highlights various modelling techniques to predict optimal machining conditions and explore the feasibility of applying WEDM process to machine advanced materials. Combined technology that benefits from the virtues of WEDM and conventional method is also highlighted in this paper. The final section discusses the development and possible research trend in WEDM process.

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Empirical modeling and optimization of kerf and wire wear ratio in wire electrical discharge machining

Cited by 33 publications

References 17 publications

Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel

Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel

Modeling and desirability approach-based multi-response optimization of WEDM parameters in machining of aluminum metal matrix composite

A progress review in wire electrical discharge machining process

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