Optimization of material removal rate and surface characterization of wire electric discharge machined Ti-6Al-4V alloy by response surface method

Deepak, Dharmpal; Shreyas, D. Sai; Bhat, Shivananda K; Rao, Rajath N.

doi:10.1051/mfreview/2022016

Cited by 11 publications

(8 citation statements)

References 41 publications

(52 reference statements)

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“…Higher spark energy emerges from a rise in the pulse current, which generates a powerful spark that raises the temperature and causes the material to melt and vaporize as well as to form craters on the workpiece. This process produces greater material removal from the surface [17]. Hence, MRR increased with increasing pulse current.…”

Section: A Mrr Results Analysismentioning

confidence: 95%

Optimization of the PM-EDM Process Parameters for Ti-35Nb-7Zr-5Ta Bio Alloy

Hayyawi,

Al-Ethari,

Haleem

2024

Eng. Technol. Appl. Sci. Res.

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Powder-Mixed Electrical Discharge Machining (PM-EDM) is one of the latest advancements in EDM process capability augmentation. This procedure involves effectively mixing a suitable material in fine powder form with the dielectric fluid. The dielectric fluid's breakdown properties are enhanced by the additional powder. The objective of the present research is to machine the Ti-35Nb-7Zr-5Ta alloy prepared by powder metallurgy and study the influence of process parameters, such as peak current, pulse-on time, pulse-off time, powder type (Ag, Si, Ag+Si), and powder concentration. The metal removal rate and SR represent the response parameters. The Taguchi approach was followed to design the experiments. The five-factor three-level design was chosen to use the Taguchi L27 orthogonal array. It was found that the addition of Ag, Si, or Ag+Si powders to the dielectric fluid enhanced the metal removal rate and the surface finish for this alloy. The addition of Ag powder to the dielectric fluid gave a higher Material Removal Rate (MRR) and a lower SR compared to Si or Ag+Si powders. Powder concentration and pulse current are the most effective parameters on MRR and SR followed by powder type, pulse-on, and pulse-off. The maximum Grey Relational Grade (GRG) exists at (I=5 A, Ton=9 µs, Toff=37 µs, PT=Ag, PC=20 g/L). These are the optimal conditions for PM-EDM of the Ti-35Nb-7Zr-5Ta alloy that give maximum MRR with minimum SR.

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Section: A Mrr Results Analysismentioning

confidence: 95%

Optimization of the PM-EDM Process Parameters for Ti-35Nb-7Zr-5Ta Bio Alloy

Hayyawi,

Al-Ethari,

Haleem

2024

Eng. Technol. Appl. Sci. Res.

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“…A piezo-electric dynamometer was used to measure the TF generated during drilling, which is the main determinant of the hole’s quality. BH was found using the Vision Measuring System (VMS), and SR was determined using the surface roughness tester—surf corder [ 22 ]. Cutting tools used in this research work were made of three different materials: HSS, carbide, and titanium nitride (TiN)-coated carbide.…”

Section: Methodsmentioning

confidence: 99%

Multi-Objective Optimization of Machining Parameters for Drilling LM5/ZrO2 Composites Using Grey Relational Analysis

et al. 2023

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In today’s world, engineering materials have changed dramatically. Traditional materials are failing to satisfy the demands of present applications, so several composites are being used to address these issues. Drilling is the most vital manufacturing process in most applications, and the drilled holes serve as maximum stress areas that need to be treated with extreme caution. The issue of selecting optimal parameters for drilling novel composite materials has fascinated researchers and professional engineers for a long time. In this work, LM5/ZrO2 composites are manufactured by stir casting using 3, 6, and 9 wt% zirconium dioxide (ZrO2) as reinforcement and LM5 aluminium alloy as matrix. Fabricated composites were drilled using the L27 OA to determine the optimum machining parameters by varying the input parameters. The purpose of this research is to find the optimal cutting parameters while simultaneously addressing the thrust force (TF), surface roughness (SR), and burr height (BH) of drilled holes for the novel composite LM5/ZrO2 using grey relational analysis (GRA). The significance of machining variables on the standard characteristics of the drilling as well as the contribution of machining parameters were found using GRA. However, to obtain the optimum values, a confirmation experiment was conducted as a last step. The experimental results and GRA reveal that a feed rate (F) of 50 m/s, a spindle speed (S) of 3000 rpm, Carbide drill material, and 6% reinforcement are the optimum process parameters for accomplishing maximum grey relational grade (GRG). Analysis of variance (ANOVA) reveals that drill material (29.08%) has the highest influence on GRG, followed by feed rate (24.24%) and spindle speed (19.52%). The interaction of feed rate and drill material has a minor impact on GRG; the variable reinforcement percentage and its interactions with all other variables were pooled up to the error term. The predicted GRG is 0.824, and the experimental value is 0.856. The predicted and experimental values match each other well. The error is 3.7%, which is very minimal. Mathematical models were also developed for all responses based on the drill bits used.

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“…Milling optimization, cutting condition, tool geometry effect, surface roughness on carbon steel by ceramic tool, cutting parameters on force/roughness and comparison of two tool's shapes were searched using Al alloy, alloyed steel, carbon steel of AISI 1045 and AISI 4140 steel [26][27][28][29][30][31] . In addition, multi-objective optimization of drilling parameters for K500 alloy, metal matrix composites, Al6061 alloy were studied using ANN, grey relation, and grey relation plus Data Envelopment Analysis Ranking (DEAR) technique [32][33][34][35] while surface characteristics of Ti-6Al-4V by RSM approaches and cutting ability of ceramic based composites in terms of energy consumption were investigated by optimizing the process [36,37] .…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimization in cutting mild steels

Şahin,

Akbar

2023

Appl. Chem. Eng.

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Machine tools are very important metal cutting process that used widely in manufacture/construction and energy sector. Material removal rate in any metal cutting process is very important because it significantly affects the production rate, generated energy/forces, tool life. Improper choice of the machine tools, cutting tools or parameters will lead to be produced early wear, more energy and deterioration of surface qualities of machined mechanical components. The cutting process should be controlled during cutting or shaping process. In this study, therefore, multi-response optimization is carried out on AISI 1040 hardened mild steels when machined with ceramic cutting tools using response surface methodology under different cutting conditions. It can be noted that there are two responses. One is the surface roughness (SR) while the second is the material removal rate (MRR). The experimental results exhibits that all three factors reveal significant influence on generating metal cutting energy. Optimal levels are found out in A3, B3 and C3 level. Namely; cutting tests are carried out at 170 m/min cutting speed, 0.15 mm/rev. feed rate and 0.5 mm depth of cut conditions in terms of multi response performance index (MRPI). Analysis of variance and Pareto chart indicate that besides basic factors, A × C, A × B, B × C interactions have also an influence on MRPI (combination of MRR with SR). It is concluded that the correlation coefficient is found about 99.06%. Therefore, MRPI approach is capable of providing good modelling results for the combination of SR and MRR.

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Optimization of material removal rate and surface characterization of wire electric discharge machined Ti-6Al-4V alloy by response surface method

Cited by 11 publications

References 41 publications

Optimization of the PM-EDM Process Parameters for Ti-35Nb-7Zr-5Ta Bio Alloy

Optimization of the PM-EDM Process Parameters for Ti-35Nb-7Zr-5Ta Bio Alloy

Multi-Objective Optimization of Machining Parameters for Drilling LM5/ZrO2 Composites Using Grey Relational Analysis

Multi-response optimization in cutting mild steels

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