Investigation on machining and surface characteristics of AA5083 for cryogenic applications by adopting trim cut in WEDM

Abstract

This paper presents the experimental investigation on wire electrical discharge machining (WEDM) of aluminum alloy 5083 (AA5083), an exotic material widely used for cryogenic applications. In this work, an attempt has been made primarily to examine the influence of number of trim cuts on WEDM for the following responses: cutting speed, surface roughness, corner error and dimensional shift. AA5083 is one of the predominant materials used in cryogenic applications. It is inevitable to comprise the inherent property and surface quality of the material in cryogenic conditions. Hence, it is identified that cutting AA5083 in WEDM is a potential process. Taguchi methodology has been used for conducting the experiments. The present work has been focused on satisfying the customer needs and demands of acquiring the expected surface quality with maximum productivity. Experimental results proved that the rough cut followed with one optimal trim cut produces maximum cutting speed with good surface quality. Besides, an expression has been derived for calculating average cutting speed and effective cutting speed in trim cuts. Furthermore, the surface integrity of the rough cut and trim cut is compared and discussed with the SEM micrographs.

Study of surface integrity and machining performance during main/rough cut and trim/finish cut mode of WEDM on Ti–6Al–4V: effects of wire material

“…This improved surface integrity in TC. Selvakumar et al [34] examined the influence of number of trim cuts on cutting speed, surface roughness, corner error and dimensional shift during WEDM of AA5083. The authors observed that rough cut followed by one optimal trim cut produced maximum cutting speed with excellent surface finish.…”

Electrical discharge machining of ceramic nanocomposites: sublimation phenomena and adaptive control

“…At the same time, the use of new oil-based ecological dielectrics makes the process even more precise and safer for the environment [12, 13, 14, 15, 16]. However, EDM has low productivity and is applicable only for conductive materials [17, 18, 19, 20].…”

Variation and artificial neural network prediction of profile areas during slant type taper profiling of triangle at different machining parameters on Hastelloy X by wire electric discharge machining

“…This phenomenon was observed because at higher cutting speed the wire lag increases. This wire lag reduces the profile areas due to increases in the corner error in outer parts as observed by Selvakumar et al 30 There are variations in decrease observed in 1mm triangle from 31%-54% at 30 and for 5mm triangle it was from 77% to 100% at 0 , 15 . As the variations were very feeble it may have been caused due to wire vibration resulting from sparking.…”

“…The β parameter majorly influences mostly on corner outer profile areas. 30 This has a very low effect on the inner profiles during machining as found in ANOVA. From the main effects plot, we can observe that there are small variations of increase and decrease in normal β, these variations were due to the errors while machining.…”

“…The wire is moved to a fixed perpendicular distance from the programmed profile that leads to an increased profile area. 26,30 The amount and direction of shift of the wire can be controlled through part programming. Figure 3(a) shows a clear increase of profile areas as the γ parameter increases for 1mm triangle.…”