Optimization of Machining Parameters of Inconel 718 by WEDM Using Response Surface Methodology

Senkathir, S.; Aravind, R.; Samson, R. Manoj; Raj, Alex Noel Joseph

doi:10.1007/978-981-13-1724-8_37

Cited by 9 publications

(4 citation statements)

References 3 publications

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“…e titanium (Ti-6Al-4V) workpiece was machined into rectangular shape of dimensions 10 × 20 mm using wire EDM machine. From the literature survey [16,17], it was finalized that the input parameters were Wire Feed, Ipeak, Pulse OFF time, and Pulse ON time. Similarly, response parameters were recast layer thickness, tool wear rate (TWR), surface roughness (Ra), and material removal rate (MRR).…”

Section: Methodsmentioning

confidence: 99%

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Samson

Sridhar

Ranjith

et al. 2022

Advances in Materials Science and Engineering

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Ti-6Al-4V is known for its lightweight, high tensile strength, exceptional corrosion resistance, and low thermal coefficient of expansion due to which it finds its application in precision surgical instruments and aeronautical and marine engine parts. In this study, Ti-6Al-4V has been machined using wire EDM machine with two different wire materials. The wire thickness of 0.25 mm heat-treated brass and zinc-coated brass tool and super cool oil as dielectric fluid were utilized for the machining process. Taguchi L9 orthogonal array was used. Ton (Pulse ON time), Toff (Pulse OFF time), wire feed, and Ip (Current) were the input parameters, and the response parameters such as surface roughness (Ra), material removal rate (MRR), tool wear rate (TWR), and recast layer thickness were optimized by TOPSIS optimization. From the results, higher tool wear rate was observed in brass tool. The titanium percentage after machining was found to be 55.05% for zinc-coated brass wire, whereas it was 51.58% for brass wire. Better productivity and surface integrity were observed in zinc-coated brass tool compared to heat-treated brass. MRR increased to 54.93%, surface roughness decreased to 2.40%, recast layer thickness increased to 3.44%, and tool wear rate was increased to 47.96%.

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Section: Methodsmentioning

confidence: 99%

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Samson

Sridhar

Ranjith

et al. 2022

Advances in Materials Science and Engineering

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“…Kumanan and Nair [16] performed multi objective optimization of performance characteristics like cylindricity, roundness, parallelism and perpendicularity using grey ANFIS. Senkathir et al [17] optimized the wire EDM parameters using RSM. The responses considered were circularity, material removal rate and surface roughness.…”

Section: Introductionmentioning

confidence: 99%

“…Effect of wire material and discharge energy on productivity and surface integrity of WEDM-processed Inconel 718 accuracies haven't considered the effect of wire electrode material and wire tensile strength [12,[15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Effect of wire material and discharge energy on productivity and surface integrity of WEDM-processed Inconel 718

Abhilash

Chakradhar

2022

Advances in Materials and Processing Technologies

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The current work aims to study the influence of discharge energy and debris accumulation on wire break failure and surface integrity aspects like surface roughness, subsurface hardness, and geometrical errors during the wire EDM of Inconel 718. The responses considered for analyzing the geometrical accuracies are flatness error, roundness error and cylindricity error. Four different wire electrodes were considered for the study based on the wire strength and coatings, namely hard zinc coated brass, half-hard zinc coated brass, hard uncoated brass, and half-hard uncoated brass wire electrodes. The geometric accuracy of the machined parts is closely related to the choice of wire electrode.High tensile strength hard wires were observed to machine the surfaces with maximum accuracy. Also, the zinc coated wires were observed to cut faster compared to the uncoated wire electrodes. The study revealed that there exists a strong influence of discharge energy on the surface integrity of wire electric discharge machined surface. The zinc and copper elemental contamination was minimal for uncoated wire electrodes at lowest discharge energy mode. Wire wear phenomena was analysed for both coated and uncoated wires. Discharge energy had a significant impact on the electrode wear of coated and uncoated wire electrode.

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“…Mathematical modelling [7] was developed for Monel 400 and artificial neural network (ANN) modelling has greater accuracy with experimental values of KF. Senkathir et al [8] led an investigation of WEDM on Inconel 718 blocks using a molybdenum wire and evaluated the SR, MRR, and circularity. Shihab et al [9] studied the effect of WEDM process parameters on frictionstir-welded 5754 aluminium alloy using the Box-Behnken design (BBD).…”

Section: Introductionmentioning

confidence: 99%

Investigation and Process Parameter Optimization on Wire Electric Discharge Machining of Aluminium 6082 Alloy

Murali

Murugan

Munimathan³

et al. 2022

Advances in Materials Science and Engineering

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Wire electrical discharge machining (WEDM) is an unconventional machining process that is being extensively used in the aerospace,medical devices, die, tooling, and automotive industries for machining high-hardness materials with conductivity. In the present work, WEDM of aluminium 6082 alloys was carried out since it influences diversified applications in manufacturing industries. The WEDM process includes an extensive number of variables that influence its execution. However, based on the literature survey, three process parameters such as pulse-on time (PTON), pulse-off time (PTOFF), and wire feed (WF) were taken into consideration. The factorial design was used for the selection of parameter levels and arrived at the 27 trails for the machining. The output responses of the WEDM, namely, surface roughness (SR), kerf width (KF), and metal removal rate (MRR) were measured, and its parameter optimization was also carried out to minimize the significant effect on productivity and the quality of components. The measured output response was compared with the predicted response surface methodology (RSM) results; it was found that the SR and KF values decreased with the increase of PTON. The MRR was increased with the increase of PTON.

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Optimization of Machining Parameters of Inconel 718 by WEDM Using Response Surface Methodology

Cited by 9 publications

References 3 publications

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Experimental Investigation of Heat-Treated Tool on Wire Electric Discharge Machining of Titanium Alloy (Ti-6Al-4V)

Effect of wire material and discharge energy on productivity and surface integrity of WEDM-processed Inconel 718

Investigation and Process Parameter Optimization on Wire Electric Discharge Machining of Aluminium 6082 Alloy

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