Multi-response optimization and modeling of trim cut WEDM operation of commercially pure titanium (CPTi) considering multiple user's preferences

Abstract

a b s t r a c tIn this research work, development of a multi response optimization technique has been undertaken, using traditional utility method in conjunction with the weight assignment concept (for multiple customer's priorities) in trim cut wire electrical discharge machining (WEDM). Pure titanium has been selected as work material for experimentation. The effect of key process parameters such a wire type (zinc coated and uncoated brass wire), pulse on time (T ON ), pulse off time (T OFF ), peak current (IP), wire feed (WF), servo voltage (SV) and wire offset (W OFF ) were investigated on material removal rate (MRR), surface roughness and wire weight consumption (eroded weight of wire after machining) in finish cut WEDM operation. Two different types of wire electrodes were taken for experimental research (uncoated, zinc coated). Further, the variation of the MRR was modeled semi-empirically through dimensional analysis. The developed model is mechanistic, as it can be used by the machinists to predict the MRR over a wide range of input parameters. The optimization of multiple responses has been done for satisfying the priorities of multiple users, in contrast to the traditional multi-response techniques where the optimized process setting is realized without giving any attention to the priorities of different users.

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

“…After completion of MC, TC is performed with low discharge energy along the same path already covered in MC with appropriate wire offset from the surface machined in previous MC. Low discharge energy supplied in TC partially (or even completely) removes various surface irregularities produced in MC [16,17]. Higher wire tension is to be set in TC as compared to MC, because bilateral discharge takes place during MC and the discharge spark imposes symmetrical force on the electrode wire.…”

Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using Response Surface Methodology

“…Kumar Jitender and Rupesh [6] (2015) study that multi response optimization technique has been undertaken by using traditional method in finish cut WEDM. In this paper pure titanium used as a work material.…”

Empirical Modeling of Average Cutting Speed during WEDM of Hastelloy C22

“…The detailed functions of each sub-element are available in reference [1,2]. From literature survey, it has been observed that most of the research work carried out on steel and steel alloys, aluminium alloys and titanium alloys [6,9,10]. Less research work has been reported on nickel-base super alloys and therefore it is very much essential to explore WEDM of nickel-base super alloys owing to its industrial importance in gas turbine and aerospace industry.…”