Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Boopathi, Sampath; Myilsamy, Sureshkumar

doi:10.5545/sv-jme.2021.7161

Cited by 43 publications

(7 citation statements)

References 16 publications

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“…The stylus of the instrument is traveled over the four different places of machined surfaces to finalize the SR values considering its mean value. Cutting rate (CR) is determined by the ratio of the volume of debris removed from the work materials concerning the time [24][25][26][27][28]. 4.…”

Section: Methodsmentioning

confidence: 99%

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Influences of cryogenically treated work material on near-dry wire-cut electrical discharge machining process

Kannan

Trabelsi

Boopathi³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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In this research, influences of cryogenically treated Inconel 718 work material in near-dry wire-cut electrical discharge machining (WEDM) characteristics have been studied using argon-mist (mixing of pressurized argon gas and minimum amount of tap-water) and a reusable Molybdenum wire tool. The effect of cutting parameters (pulse width (PW), spark current(C), pulse interval (PI), and flow rate(F)) on surface roughness (SR) and cutting rate (CR) and using Box-Behnken response surface analysis. It was observed that CR and SR are increased by increasing PW, and C; conversely, reduced by increasing PI. The technique for order of preference by similarity to ideal solution (TOPSIS) method has been utilized to estimate the best parameters’ settings for improving both machining characteristics. The optimum CR (9.81 mm3/min) and SR (1.9 µm) have been obtained by optimum settings of 4 Ampere spark current, PW of 20µs, PI of 72µs, and 18ml/min of the flow rate of mixing water using the TOPSIS method. The best settings of cutting parameters obtained from the TOPSIS method were considered to compare the near-dry WEDM performance using cryogenically treated/ untreated work materials. It was observed that CR and SR of the cryogenically treated work material are 9.17% increased and 21.58% reduced than the untreated work material due to an increase in electrical and thermal conductivities.

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Section: Methodsmentioning

confidence: 99%

“…Chemical elements of Inconel 718 alloy.Thus, the cutting parameters have been selected based on the previous near-dry experiments and pre-setting levels of the WEDM machine[24,29,30]. The cutting parameters and their levels are displayed in table3.The first eight experiments are decided based on two levels of four-factor design (2×4=8).…”

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confidence: 99%

Influences of cryogenically treated work material on near-dry wire-cut electrical discharge machining process

Kannan

Trabelsi

Boopathi³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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“…The sequential sum of the square test was used to create the mathematical models for each response utilizing substantial individual, interaction, and quadratic variables. [23] Timur Rizovich Ablyaz et al , presented the study paper Analysis of Wire-Cut Electro Discharge Machining of Polymer Composite Materials was presented. The examination of wire-cut electro-discharge machining (WIRE-EDM) of polymer composite material (PCM) is presented in this work.…”

Section: Selection Of Materialsmentioning

confidence: 99%

Recent Research in Wire Cut Electrical Discharge Machining Process

2024

jmc

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A product's shape and size are developed through the manufacturing process, which is essential to all sectors. With its unique thermal machining technique, Wire Cut Electrical Discharge Machining (WEDM), items with sharp edges and varied hardness that prove challenging to produce using conventional machining methods can be precisely machined. Utilizing the widely used non-contact material removal technique, the practical technology of the WEDM process is based on the typical EDM sparking phenomenon. When the process was first introduced, WEDM has developed from a crude way to make tools and dies to the best way to produce micro-scale parts with the highest level of surface finish quality and dimensional accuracy. This paper reviews the extensive amount of research done from the EDM process to the development of the WEDM. It reports on the WEDM research that involves optimizing the process parameters and examining the impact of various factors on productivity and machining performance. The impact of multiple WEDM process input parameters, including wire speed, peak current, pulse on and off times, and peak on material removal rate (MRR), surface roughness (Ra), and micro structural analysis, on various process output responses is reviewed in this study.

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“…The essential role of the dielectric fluid is to flush out the machined debris and provide dielectric strength. In the conventional EDM process, the dielectric fluid is decomposed and harmful gases are emitted to affect the human operators [1,40]. In the dry EDM process, an air or gas medium has been employed to perform the flushing and cooling processes.…”

Section: Machining Mechanism Of Graphite Powder-argon Gas Assisted De...mentioning

confidence: 99%

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

Janardhana

Anushkannan²,

Dinakaran

et al. 2023

Eng. Res. Express

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In this research, the environment-friendly dry electrical discharge machining (EDM) process is investigated to improve the microhardness, surface finish, and white layer thickness of the machined surfaces using graphite-argon gas as a dielectric medium. The graphite powder, mixed with compressed argon gas, has been used to replace the existing dielectric medium in the EDM process. Gas pressure, discharge current, pulse width, and gap voltage were working as input parameters to reduce surface roughness and enhance the microhardness and white layer thickness. The Taguchi L16 orthogonal array is applied to the design and analysis of the experimental results. The minimum surface roughness (2.23 µm) of the HN31 steel has been attained by increasing the gas pressure up to 1.0 MPa and the minimum values of pulse width (40 µs), gap voltage (40 V), and discharge current (6 A). The maximum microhardness (501.04 HV) has been obtained at 1.2 MPa of gas pressure, 120 µs of pulse width, 60 V of gap voltage, and 18 A of discharge current. The maximum white layer thickness (16.24 µm) is achieved by the maximum values of gas pressure (1.2 MPa), pulse width (160 µs), gap voltage (70 V) and discharge current (18 A). The SEM analysis had been done to reveal the white recast layer thickness and surface roughness of the machined surfaces of the dry EDM process. The SR is increased by the recast layer, pores, and microcracks on the machined surfaces. Finally, the multi-criteria optimization technique: Weight Product Method (WPM) is applied to predict optimum process parameter settings: GP: 1.2 MPa, PW: 120 µs, GV: 50 V, and DC: 18 A to meet the best machining performances (MH=493.32 HV, WLT= 14.28 µm, and SR= 3.82 µm). The validation tests were done to confirm the predicted results obtained by both the Taguchi and WSM methods.

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Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Cited by 43 publications

References 16 publications

Influences of cryogenically treated work material on near-dry wire-cut electrical discharge machining process

Influences of cryogenically treated work material on near-dry wire-cut electrical discharge machining process

Recent Research in Wire Cut Electrical Discharge Machining Process

Experimental investigation on microhardness, surface roughness, and white layer thickness of dry EDM

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