The effect of machining parameters on surface roughness and material removal rate with cryogenic treated wire in WEDM

Kapoor, Jatinder; Khamba, Jaimal Singh; Singh, Sehijpal

doi:10.1504/ijmmm.2012.048562

Cited by 8 publications

(5 citation statements)

References 12 publications

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“…MRR-1 and MRR-2 display the same trend for the increase in WF rate as that of T ON , indicating that higher WF rate is essential for good MRR. Kapoor et al [29] also obtained the same results, whereby the MRR increased with WF rate. However, the values of both R a s do not tend to have a particular proportionality with the increase in WF rate.…”

Section: Resultsmentioning

confidence: 55%

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Kumar¹,

Prasanna²

2022

Materials Science-Poland

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The present investigation aimed to determine the optimal parameters for wire-cut electrical discharge machining (WEDM) for stir cast aluminum alloy AA6063 at 850°C reinforced with 10 wt.% green SiC (SiC g ) and black SiC (SiC b ) particles. The WEDM machining parameters, such as pulse on time (TON ), wire feed (WF) rate, and flushing pressure (FP) of the resultant stir cast AA6063/SiC b and AA6063/SiC g composites, were optimized using the Taguchi method with L9 orthogonal array to estimate the responses, such as surface roughness and metal removal rate. Further, through grey relational analysis, the finest parameters for WEDM of AA6063/SiC b and AA6063/SiC g composites were evaluated as TON = 50 μs, WF rate = 18 m/min, and FP = 3 MPa. With the optimum parameters obtained, conformational experiments were conducted, and the scanning electron microscopic images were recorded, along with the energy-dispersive X-ray (EDX) spectroscopic data of the worn surfaces and debris. From the EDX mapping images of the machined surface, it was evident that AA6063/SiC b displays a more polished surface than AA6063/SiC g . However, for applications requiring a high metal removal rate, AA6063/SiC g displays better results than AA6063/SiC b .

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Section: Resultsmentioning

confidence: 55%

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Kumar¹,

Prasanna²

2022

Materials Science-Poland

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“…Many researchers have adopted cryogenic processing to achieve significant improvement in machining performance of the EDM and WEDM process (Kapoor et al, 2012a(Kapoor et al, , 2012b. In this direction, Kumar et al (2012) have investigated the machinability of Inconel 718 work material with ceramic powder mixed in dielectric fluid using cryogenically treated copper electrode in electrical discharge machining.…”

Section: Literature Reviewmentioning

confidence: 99%

“…In this direction, Kumar et al (2012) have investigated the machinability of Inconel 718 work material with ceramic powder mixed in dielectric fluid using cryogenically treated copper electrode in electrical discharge machining. Kapoor et al (2012a) have investigated the effect of deep cryogenic treated brass wire electrode using Taguchi experimental design. From the ANOVA, it is observed that wire type, pulse width, time between two pulses and wire tension are important parameters for improving material removal rate.…”

Section: Literature Reviewmentioning

confidence: 99%

“…Cryogenic treatment also causes longer part life, less failure due to cracking, improved thermal properties, better electrical properties and improved machinability (Kumar et al, 2012, Rahul et al, 2017. In recent times, cryo-processing has been successfully applied in non-conventional machining processes resulting in successful application in electrical discharge machining (EDM) and wire EDM through treatment of electrodes and wires which are used for machining of toughened and high strength to weight ratio materials (Kumar et al, 2012;Jafferson and Hariharan, 2013;Gill and Singh, 2010;Kapoor et al, 2012aKapoor et al, , 2012b. However, the effect of deep cryogenic treatment on both wire electrode and work piece material during taper cutting operation in WEDM process is not adequately addressed in the literature.…”

Section: Introductionmentioning

confidence: 99%

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Effect of deep cryogenic treatment on performance measures in wire electrical discharge machining process during taper cutting operation

Nayak

Mahapatra

2019

IJPQM

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Deep-cryogenic treatment brings some remarkable improvements in mechanical properties by refining the microstructure of the materials. In recent times, cryo-processing has been successfully applied to toughened and high strength to weight ratio work piece materials and tools in electrical discharge machining (EDM) and wire electrical discharge machining (WEDM) for improving machining efficiency. In the present investigation, coated Bronco cut-W wire electrode and Inconel 718 work piece are subjected to deep cryogenic treatment (-196°C). The microstructure of deep cryo-treated and untreated wire electrode and work piece is observed by scanning electron microscope (SEM). The effect of deep cryogenically treated wire electrode and work piece on various performance characteristics are studied during taper cutting operation in WEDM process. Taguchi's experimental design has been applied to determine the optimal parameter setting considering six input parameters such as part thickness, taper angle, pulse duration, discharge current, wire speed and wire tension on various performance measures such as angular error, surface roughness and cutting speed. The study reveals that deep cryogenic treatment of both wire electrode and work piece can improve the machining performance in WEDM.

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“…The EDM achieved highest MRR, SR, TWR and dimensional accuracy when workpiece and tool (electrode) done by cryogenic treatment [11]. Similarly, when wire EDM was machining the work piece after plasma nitriding, there were no significant changes of formation of white layer on surface [10]. The hardening with double tempering gives better surface roughness compared to single tempering [13].…”

Section: Introductionmentioning

confidence: 95%

Influence of optimization techniques and nano surface coating materials on microstructure of iron-nickel-chromium alloy using wire EDM process

Selvabharathi¹,

Srinivasan

Sivaprakasam

2021

Materials Science-Poland

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This research proposes developing the new hybrid optimization techniques for getting optimized wire EDM machining parameters and analysing the performance and microstructure of hybrid treatment alloy 20 material (high-velocity oxygen fuel spraying and plasma nitriding on iron-nickel-chromium alloy) after machining in wire EDM. The devising optimization is carried out using back-propagation neural networks (BPNN) integrated with fuzzy logic techniques. Taguchi L27 method uses optimized parameters in 3 factors and 3 level methods to BPNN wire EDM processing parameters. Those processing parameter errors are controlled by applying fuzzy logic system in hybrid optimization techniques. The hybrid optimization provides best results (±5% error) while comparing other techniques. This proposal was started with research review of defined factors and BPNN parameters level for hidden layer number, learning algorithm, neurons numbers, and so on. The analysis of variance (ANOVA), analysis of means (ANOM) and signal to noise (S/N) ratio have been used to identify Taguchi results. The BPNN techniques have been employed significantly to tackle hidden layer's uncertain parameter structures. The fuzzy logic controllers in general have been designed engaging the relations between system performance and factor through error method calculation. The microstructure analysis showed that the no evidence was found of recast layer formation on hybrid treated material after machining in wire EDM due to compressive stress and compound layer on material surface.

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The effect of machining parameters on surface roughness and material removal rate with cryogenic treated wire in WEDM

Cited by 8 publications

References 12 publications

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Parameter optimization for wire-cut electrical discharge machining of stir cast AA6063 alloy/SiC (black and green) using Taguchi method with grey relational analysis

Effect of deep cryogenic treatment on performance measures in wire electrical discharge machining process during taper cutting operation

Influence of optimization techniques and nano surface coating materials on microstructure of iron-nickel-chromium alloy using wire EDM process

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