Semi-empirical model on MRR and overcut in WEDM process of pure titanium using multi-objective desirability approach

Abstract

Titanium and its alloys have been experiencing extensive development over the past few decades stimulated by a series of their unique properties, i.e. high strength to weight ratio maintained at elevated temperature, high hot hardness, high fracture resistance, and exceptional resistance to corrosion at temperature below 500°C. Machining of titanium, however, is considered as cumbersome with the conventional manufacturing practices, and there is a critical need for developing and establishing cost-effective methods of machining. This research work is mainly focused on the effect of WEDM parameters, such as pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate and wire tension has been varied to investigate their effect on material removal rate and overcut for pure titanium. The experiments are planned, conducted, and analyzed through response surface methodology. An attempt has also been made to construct a micro-model for prediction of material removal rate using dimensional analysis. The predictions from this model have been validated by conducting experiments.

Experimental investigation and modelling of WEDM process for machining nano-structured hardfacing material

“…This behavior can be explained by the fact that at high discharge pulse time, the intensity of the spark will be greater, which will in turn remove relatively large amount of material from the sparking zone resulting in high MRR. This is an agreement with other researchers [18,19]. Figure 3a shows that when discharge pulse time is increased from 0.3 to 0.5 µs, the material removal rate increased significantly.…”

“…Response surface methodology (RSM) is a collection of mathematical and statistical techniques useful for modeling and analysis of manufacturing problems [19]. RSM was performed to correlate the various WEDM parameters and performance measures.…”

A semi-empirical model to predict material removal rate during air-assisted electrical discharge machining

“…The model was developed considering, thermo-physical properties of Inconel 718, machining and orbital parameters. Kumar et al [15] used response surface methodology (RSM) method to conduct and analyze the effects of parameters involved in WEDM to assess its effect on MRR and over-cut for pure titanium. Further, they developed a model to predict MRR by Buckingham π-theorem.…”

An overview of conventional and non-conventional techniques for machining of titanium alloys

“…The different tool types and grades that are used in conventional machining operations are listed in Table S1 [ 117,[119][120][121][124][125][126][127][128][129][130][131][132]. Although different tool wear mechanisms such as plastic deformation, adhesion and abrasion were mentioned in the preceding paragraphs, crater wear has been reported as the main mechanisms affecting the life span of cutting tools especially at cutting speed of 61-122 m/min [33,88].…”