Performance Analysis of Wire Electrodes on Machining<i>Ti-6Al-4V</i>Alloy using Electrical Discharge Machining Process

Ramamurthy, A. C.; Sivaramakrishnan, R.; Muthuramalingam, T.; Venugopal, S.

doi:10.1080/10910344.2015.1085314

Cited by 53 publications

(21 citation statements)

References 12 publications

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“…Capacitance was found as the most significant factor influencing machining characteristics remarkably. Ramamurthy et al [24] analysed the influence of wire electrode on kerf width and surface roughness during WEDM of Ti-6Al-4V. Amongst conventional brass wire, zinc-coated brass wire and diffused coated wire, the machining performance was found superior for diffused coated wire.…”

Section: State Of Artmentioning

confidence: 99%

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

Jadam

Datta

Masanta

2019

J Braz. Soc. Mech. Sci. Eng.

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Due to increased demand of dimensional accuracy and high precision of manufactured parts, wire electrical discharge machining (WEDM) became very popular, especially for 'difficult-to-cut' materials like titanium alloys. Grade 5 Ti alloy (Ti-6Al-4V) has enormous application in aerospace and biomedical fields. WEDM performance of Ti-6Al-4V is somewhat restricted due to its poor thermal conductivity, formation of hard and brittle carbide-/oxide-rich layer and often surface cracking which affect fatigue performance of the part product. Therefore, multi-cut strategy is adapted to mitigate machining-induced defects. The multi-cut mode consists of one main/rough cut followed by a number of trim/finish cuts. Aspects of surface integrity of the WEDMed Ti-6Al-4V obtained in different modes of cut are delineated in this reporting. Three slots are produced: (1) main cut; (2) main cut followed by one trim cut; and (3) main cut followed by two trim cuts using uncoated brass wire and zinc-coated brass wire, respectively. Surface morphology along with topographical features including roughness average, crack density, recast layer thickness, material immigration, residual stress and micro-indentation hardness is studied. Results obtained thereof are analysed with relevance to kerf width, material removal rate and wire wear.

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Section: State Of Artmentioning

confidence: 99%

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

Jadam

Datta

Masanta

2019

J Braz. Soc. Mech. Sci. Eng.

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“…Increase in T on resulted in increase in MRR. In another study by Ramamurthy et al [21], machining of Ti6Al4V alloy was conducted using the EDM process by using Taguchi L9 orthogonal array. They observed that T off has more influent nature on the output performances of machining characteristics because the T off influences the discharge energy in WEDM.…”

Section: Introductionmentioning

confidence: 99%

“…WEDM is a multi-input multi-output process encompassing complex dependencies on individual parameters as well as their interactions [21,22]. Generally, wherever multiple objectives are considered, several conflicting situations arise wherein there is a requirement is to settle at a tradeoff between these multiple responses.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of WEDM Process Parameters for Machining of Superelastic Nitinol Shape-Memory Alloy Using a Heat-Transfer Search Algorithm

et al. 2019

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Nitinol, a shape-memory alloy (SMA), is gaining popularity for use in various applications. Machining of these SMAs poses a challenge during conventional machining. Henceforth, in the current study, the wire-electric discharge process has been attempted to machine nickel-titanium (Ni55.8Ti) super-elastic SMA. Furthermore, to render the process viable for industry, a systematic approach comprising response surface methodology (RSM) and a heat-transfer search (HTS) algorithm has been strategized for optimization of process parameters. Pulse-on time, pulse-off time and current were considered as input process parameters, whereas material removal rate (MRR), surface roughness, and micro-hardness were considered as output responses. Residual plots were generated to check the robustness of analysis of variance (ANOVA) results and generated mathematical models. A multi-objective HTS algorithm was executed for generating 2-D and 3-D Pareto optimal points indicating the non-dominant feasible solutions. The proposed combined approach proved to be highly effective in predicting and optimizing the wire electrical discharge machining (WEDM) process parameters. Validation trials were carried out and the error between measured and predicted values was negligible. To ensure the existence of a shape-memory effect even after machining, a differential scanning calorimetry (DSC) test was carried out. The optimized parameters were found to machine the alloy appropriately with the intact shape memory effect.

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“…Different wire electrodes are also used such as brass wire, zinc coated wire and diffused coated wire. It was noticed that diffused coated wire provides better surface finish and minimum kerf width [14]. Use of oxygen gas as a medium synergizes sparking with oxidation and results in enhanced metal removal and machining rate [15].…”

Section: Introductionmentioning

confidence: 99%

Effect of different dielectric fluids on material removal rate, surface roughness, kerf width and microhardness

Chaudhary

Chanda²,

Siddiquee

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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In microelectro discharge machining, dielectric plays prime role in the machining performance. The performance of machining is highly affected by dielectric fluid used in the micro-EDM. This paper discusses the influence of various different dielectric fluids such as demineralised (DM) water, oxygenated DM water, mixture of ethylene glycol and DM water, alumina suspension in DM water, alumina suspension in oxygenated DM water and alumina suspension in mixture of ethylene glycol and oxygenated DM water on the performance criteria such as material removal rate (MRR), surface roughness, kerf width and microhardness during the machining of stainless steel. The results show that the use of DM water as a dielectric gives high MRR. Also when non-conducting alumina powder is mixed with dielectric, the MRR is decreased. Surface roughness is best for DM water. Surface roughness is found to increase with other dielectric fluids. Kerf width is improved after mixing alumina powder and ethylene glycol to DM water. A comparative study for microhardness has also been done for different dielectric fluids. Further study is done using microscope to analyze the microstructure. Further investigation is performed on surface integrity in each type of dielectric with the help of microstructure. Hence, micro-EDM is performed on stainless steel with different dielectric fluids. It is noticed from the results that there is significant impact of mixing non-conducting alumina powder and oxygen in DM water which increased the kerf width and microhardness of machined surface in micro-EDM of stainless steel.

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Performance Analysis of Wire Electrodes on MachiningTi-6Al-4VAlloy using Electrical Discharge Machining Process

Cited by 53 publications

References 12 publications

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

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

Multi-Response Optimization of WEDM Process Parameters for Machining of Superelastic Nitinol Shape-Memory Alloy Using a Heat-Transfer Search Algorithm

Effect of different dielectric fluids on material removal rate, surface roughness, kerf width and microhardness

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