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Article
Publication date: 9 March 2020

Multi-objective optimization of wire electrical discharge machining of 20MnCr5 alloy steel

Naresh Kumar and Khushdeep Goyal

Wire electric discharge machining (WEDM) is a non-conventional machining process, which is used to provide difficult and intricate shapes. The purpose of this research…

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Abstract

Purpose

Wire electric discharge machining (WEDM) is a non-conventional machining process, which is used to provide difficult and intricate shapes. The purpose of this research work is to apply Taguchi’s technique to optimize the process parameters in WEDM. Alloy steel 20MnCr5 has been selected as base material for experimentation. The effects of the input process parameters such as wire type, pulse-on time, pulse-off time, peak current, wire feed rate and servo voltage have been calculated on the material removal rate (MRR) and surface roughness (Ra) in WEDM operation.

Design/methodology/approach

In the research work, Taguchi's technique is applied to optimize the process parameters in WEDM.

Findings

ANOVA indicated that pulse-off time was the most significant factor for the MRR, and servo voltage was the most significant factor for surface roughness (SR). As a part of the project, 20MnCr5 was machined in wire electric discharge machine, and the optimal control parameters were found to get higher MRR and better SR using Taguchi’s technique.

Originality/value

To the best of authors’ knowledge, after reviewing the literature, materials including alloys of metals such as 16MnCr5 and 20MnCr5 have not been investigated so far, and research regarding machining of these materials is limited. Therefore, 20MnCr5 material has been selected for this research work to generate WEDM data.

Details

World Journal of Engineering, vol. 17 no. 3
Type: Research Article
DOI: https://doi.org/10.1108/WJE-09-2017-0304
ISSN: 1708-5284

Keywords

  • WEDM
  • Taguchi
  • Orthogonal array
  • Process parameters
  • MRR
  • SR and 20MnCr5

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Article
Publication date: 4 November 2019

Performance evaluation of cryogenically treated wires during wire electric discharge machining of AISI D3 die tool steel under different cutting environments

Husandeep Sharma, Khushdeep Goyal and Sunil Kumar

Tool steel (AISI D3) is a preferred material for industrial usage. Some of the typical applications of D3 tool steel are blanking and forming dies, forming rolls, press…

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Abstract

Purpose

Tool steel (AISI D3) is a preferred material for industrial usage. Some of the typical applications of D3 tool steel are blanking and forming dies, forming rolls, press tools and punches bushes. It is used under conditions where high resistance to wear or to abrasion is required and also for resistance to heavy pressure rather than to sudden shock is desirable. It is a high carbon and high chromium steel. Therefore, wire electric discharge machining (WEDM) is used to machine this tool steel. The paper aims to discuss these issues.

Design/methodology/approach

The present experimental investigation evaluates the influence of cryogenically treated wires on material removal rate (MRR) and surface roughness (SR) for machining of AISI D3 steel using the WEDM process. Two important process responses MRR and SR have been studied as a function of four different control parameters, namely pulse width, time between two pulses, wire mechanical tension and wire feed rate.

Findings

It was found that pulse width was the most significant parameter which affects the MRR and SR. Better surface finish was obtained with cryogenically treated zinc coated wire than brass wire.

Originality/value

The review of the literature indicates that there is limited published work on the effect of machining parameters in WEDM in cryogenic treated wires. Therefore, in this research work, it was decided to evaluate the effect of cryogenically treated wires on WEDM.

Details

Multidiscipline Modeling in Materials and Structures, vol. 15 no. 6
Type: Research Article
DOI: https://doi.org/10.1108/MMMS-04-2019-0078
ISSN: 1573-6105

Keywords

  • Parameters
  • Surface finish
  • Cryogenics
  • Material removal rate
  • Tool steel

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Article
Publication date: 12 August 2019

Optimization of process parameters of wire electro discharge machining for Ti49.4Ni50.6 shape memory alloys using the Taguchi technique

Adik Takale and Nagesh Chougule

Ti49.4Ni50.6 (at. %) shape memory alloy (SMA) is a unique class of smart materials because of unbeatable property which given a wide variety of their applications across a…

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Abstract

Purpose

Ti49.4Ni50.6 (at. %) shape memory alloy (SMA) is a unique class of smart materials because of unbeatable property which given a wide variety of their applications across a broad range of fields including an orthopedic implant. It plays a very important role in the constructions of novel orthopedic implants application (like dynamic compression plate) because of lower Young’s modulus compared to other biomedical implant materials, high mechanical strength, excellent corrosion resistance and unique property like shape memory effect. Conventional machining of Ti-Ni yields poor surface finish and low dimensional accuracy of the machined components. Hence, wire electro-discharge machining (WDEM) of Ti-Ni has been performed. The purpose of this paper is to investigate the effect of variation of five process parameters, namely, a pulse-on time, pulse-off time, spark gap set voltage (SV), wire feed and wire tension on the material removal rate, surface roughness (SR), kerf width (KW) and dimensional deviation (DD), in the WDEM of Ti49.5Ni50.6 SMA.

Design/methodology/approach

The effect of machining parameters on Ti49.4Ni50.6 has been fully explored using WEDM with zinc coated brass wire as an electrode. In this work, L18 orthogonal array based on Taguchi method has been used to conduct a series of experiments and statically evaluate the experimental data by the use of the method of analysis of variance. Scanning electron microscope images of the machined surface, at the highest and lowest pulse-on time, have been taken to evaluate the quality of surface in terms of their SR values.

Findings

For the highest pulse-on time, it is observed that blow holes, cracks, melted droplets and craters have been formed on the machined surface with an SR of 2.744 µm, while for the lowest pulse-on time, these are not formed with an SR of 0.862 µm. It is seen that the pulse-on time is the most significant process parameter for MRR, SR and KW, while the DD is significantly affected by spark gap SV. The optimal values of the process parameters have been obtained by the method of analysis of mean and the confirmatory experiments have been carried out to validate results of optimization. Energy dispersive spectroscopy analysis of the machined surface of Ti49.4Ni50.6 has shown a certain amount of deposition of material on the machined surface.

Originality/value

This is an original paper.

Details

International Journal of Structural Integrity, vol. 10 no. 4
Type: Research Article
DOI: https://doi.org/10.1108/IJSI-10-2018-0058
ISSN: 1757-9864

Keywords

  • Analysis of variance
  • Shape memory alloy
  • Taguchi design

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Article
Publication date: 14 March 2020

Optimization of WEDM process parameters in machining Nimonic 75 alloy using brass wire

Harvinder Singh, Vinod Kumar and Jathinder Kapoor

An experimental study has been conducted to model and optimize wire electric discharge machining (WEDM) process parameters such as pulse-on time, pulse-off time, servo…

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Abstract

Purpose

An experimental study has been conducted to model and optimize wire electric discharge machining (WEDM) process parameters such as pulse-on time, pulse-off time, servo voltage and peak current for response characteristics during machining of Nimonic 75 alloy.

Design/methodology/approach

The response surface methodology (RSM)-based Box–Behnken's design has been employed for experimental investigation. RSM is used for developing quadratic regression models for selected response variables i.e. material removal efficiency and kerf width. To validate the model, confirmation experiments have been performed. The multi-response optimization has been done using desirability function approach.

Findings

Through analysis of variation, the percent contribution of process parameters on the response characteristics has been found. Pulse-off time is the most significant parameter affecting the kerf width and material removal efficiency followed by pulse-on time. The quadratic regression models have been developed for prediction of selected response variables. An attempt has been made to optimize the WEDM parameters for material removal efficiency and kerf width. The recommended process parameter setting for maximum material removal efficiency and minimum kerf width have been found to be pulse-on time = 0.6 µs, pulse-off time = 14 µs, servo voltage = 25 V and peak current = 200 A.

Originality/value

The “kerf width” is an important response variable for maintaining dimensional accuracy of the machined component, but has not been given due attention by the researchers. In the present work, the developed regression model for “kerf width” can be used in estimating wire offset setting and thereby getting a dimensionally accurate product. The optimum process parameters obtained in WEDM of Nimonic 75 alloy will contribute in database of machining. The outcome of this study would be added to scare database of the machining of Nimonic 75 alloy and also would be extremely useful for making the technology charts for WEDM.

Details

Multidiscipline Modeling in Materials and Structures, vol. 16 no. 5
Type: Research Article
DOI: https://doi.org/10.1108/MMMS-10-2019-0178
ISSN: 1573-6105

Keywords

  • Wire electrical discharge machining
  • Nimonic 75
  • Optimization
  • Analysis of variance
  • Kerf width
  • Material removal efficiency and desirability function approach

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Article
Publication date: 23 March 2020

Effect of WEDM process parameters on machinability of Nimonic75 alloy using brass wire

Harvinder Singh, Vinod Kumar and Jatinder Kapoor

This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly…

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Abstract

Purpose

This study aims to investigate the influence of process parameters of wire electrical discharge machining (WEDM) of Nimonic75. Nimonic75 is a Nickel-based alloy mostly used in the aerospace industry for its strength at high temperature.

Design/methodology/approach

One factor at a time (OFAT) approach has been used to perform the experiments. Pulse on time, pulse off time, peak current and servo voltage were chosen as input process parameters. Cutting speed, material removal rate and surface roughness (Ra) were selected as output performance characteristics.

Findings

Through experimental work, the effect of process parameters on the response characteristics has been found. Results identified the most important parameters to maximize the cutting speed and material removal rate and minimize Ra.

Originality/value

Very limited research work has been done on WEDM of Nickel-based alloy Nimonic75. Therefore, the aim of this paper to conduct preliminary experimentation for identifying the parameters, which influence the response characteristics such as material removal rate, cutting speed, Ra, etc. during WEDM of Nickel-based alloy (Nimonic75) using OFAT approach and found the machinability of Nimonic75 for further exhaustive experimentation work.

Details

World Journal of Engineering, vol. 17 no. 3
Type: Research Article
DOI: https://doi.org/10.1108/WJE-09-2019-0277
ISSN: 1708-5284

Keywords

  • Optimization
  • Wire electrical discharge machining (WEDM)
  • Material removal rate
  • Cutting speed
  • Surface roughness
  • One factor at a time (OFAT) approach

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Article
Publication date: 10 May 2019

A DoE–TOPSIS method-based meta-model for parametric optimization of non-traditional machining processes

Shankar Chakraborty, Prasenjit Chatterjee and Partha Protim Das

To meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries…

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Abstract

Purpose

To meet the requirements of high-dimensional accuracy and surface finish of various advanced engineering materials for generating intricate part geometries, non-traditional machining (NTM) processes have now become quite popular in manufacturing industries. To explore the fullest machining capability of these NTM processes, it is often required to operate them while setting their different controllable parameters at optimal levels. This paper aims to present a novel approach for selection of the optimal parametric mixes for different NTM processes in order to assist the concerned process engineers.

Design/methodology/approach

In this paper, design of experiments (DoE) and technique for order preference by similarity to ideal solution (TOPSIS) are combined to develop the corresponding meta-models for identifying the optimal parametric combinations of two NTM processes, i.e. electrical discharge machining (EDM) and wire electrical discharge machining (WEDM) processes with respect to the computed TOPSIS scores.

Findings

For EDM operation on Inconel 718 alloy, lower settings of open circuit voltage and pulse-on time and higher settings of peak current, duty factor and flushing pressure will simultaneously optimize all the six responses. On the other hand, for the WEDM process, the best machining performance can be expected to occur at a parametric combination of zinc-coated wire, lower settings of pulse-on time, wire feed rate and sensitivity and intermediate setting of pulse-off time.

Practical implications

As the development of these meta-models is based on the analysis of the experimental data, they are expected to be more practical, being immune to the introduction of additional parameters in the analysis. It is also observed that the derived optimal parametric settings would provide better values of the considered responses as compared to those already determined by past researchers.

Originality/value

This DoE–TOPSIS method-based approach can be applied to varieties of NTM as well as conventional machining processes to determine the optimal parametric combinations for having their improved machining performance.

Details

Journal of Modelling in Management, vol. 14 no. 2
Type: Research Article
DOI: https://doi.org/10.1108/JM2-08-2018-0110
ISSN: 1746-5664

Keywords

  • Optimization
  • Modelling
  • Manufacturing
  • Design of experiments
  • TOPSIS
  • Meta-model
  • Non-traditional machining process
  • Process parameter
  • Response

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Article
Publication date: 14 February 2020

Performance analysis in WEDM of titanium grade 6 through process capability index

Himadri Majumder and Kalipada Maity

The purpose of this study aims to obtain excellent products, consistent investigation and manufacturing process control which are the preconditions that organizations have…

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Abstract

Purpose

The purpose of this study aims to obtain excellent products, consistent investigation and manufacturing process control which are the preconditions that organizations have to consider. Nowadays, manufacturing industry apprise process capability index (Cpi) to evaluate the nature of their things with an expect to enhance quality and also to improve the productivity by cutting down the operating cost. In this paper, process capability analysis was applied during wire electrical discharge machining (WEDM) of titanium grade 6, to study the process performance within specific limits.

Design/methodology/approach

Four machine input parameters, namely, pulse ON time, pulse OFF time, wire feed and wire tension, were chosen for process capability study. Experiments were carried out according to Taguchi’s L27 orthogonal array. The value of Cpi was evaluated for two machining attributes, namely, average surface roughness and material removal rate (MRR). For these two machining qualities, single response optimization was executed to explore the input settings, which could optimize WEDM process ability.

Findings

Optimum parameter settings for average surface roughness and MRR were found to be TON: 115 µs, TOFF: 55 µs, WF: 4 m/min and WT: 6 kg−F and TON: 105 µs, TOFF: 60 µs, WF: 4 m/min and WT: 5 kg−F.

Originality/value

Process capability analysis constantly checks the process quality through the capability index keep in mind the end goal to guarantee that the items made are complying with the particulars, providing data for product plan and process quality enhancement for designer and engineers, giving the support to decrease the cost of item failures.

Details

World Journal of Engineering, vol. 17 no. 1
Type: Research Article
DOI: https://doi.org/10.1108/WJE-04-2019-0126
ISSN: 1708-5284

Keywords

  • Surface roughness
  • MRR
  • Process capability analysis
  • WEDM

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Article
Publication date: 1 February 1999

Design of experiments to study and optimize process performance

R. Konda, K.P. Rajurkar, R.R. Bishu, A. Guha and M. Parson

Design of experiments is one of the many problem‐solving quality tools that can be used for various investigations such as finding the significant factors in a process…

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Abstract

Design of experiments is one of the many problem‐solving quality tools that can be used for various investigations such as finding the significant factors in a process, the effect of each factor on the outcome, the variance in the process, troubleshooting the machine problems, screening the parameters, and modeling the processes. Many industries use this tool to stay competitive worldwide by designing robust products as well as improving quality and reliability of a product. By using strategically designed and statistically performed experiments, it is possible to study the effect of several variables at one time, and to study inter‐relationships and interactions. Proposes a strategy to apply the design of experiments to study and optimize the performance of a process. Additionally, the formulation and solution to a multi‐objective optimization problem have been presented. As a case study, experimental design technique used by the authors to study the performance of a wire electrical discharge machining process for machining beryllium copper alloys is presented.

Details

International Journal of Quality & Reliability Management, vol. 16 no. 1
Type: Research Article
DOI: https://doi.org/10.1108/02656719910226914
ISSN: 0265-671X

Keywords

  • Design of experiments
  • Machining
  • Optimization
  • Process efficiency
  • Taguchi methods

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Article
Publication date: 26 July 2011

Application of Self Organizing Map (SOM) to model a machining process

Mohamad Saraee, Seyed Vahid Moosavi and Shabnam Rezapour

This paper aims to present a practical application of Self Organizing Map (SOM) and decision tree algorithms to model a multi‐response machining process and to provide a…

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Abstract

Purpose

This paper aims to present a practical application of Self Organizing Map (SOM) and decision tree algorithms to model a multi‐response machining process and to provide a set of control rules for this process.

Design/methodology/approach

SOM is a powerful artificial neural network approach used for analyzing and visualizing high‐dimensional data. Wire electrical discharge machining (WEDM) process is a complex and expensive machining process, in which there are a lot of factors having effects on the outputs of the process. In this work, after collecting a dataset based on a series of designed experiments, the paper applied SOM to this dataset in order to analyse the underlying relations between input and output variables as well as interactions between input variables. The results are compared with the results obtained from decision tree algorithm.

Findings

Based on the analysis of the results obtained, the paper extracted interrelationships between variables as well as a set of control rules for prediction of the process outputs. The results of the new experiments based on these rules, clearly demonstrate that the paper's predictions are valid, interesting and useful.

Originality/value

To the best of the authors' knowledge, this is the first time SOM and decision tree has been applied to the WEDM process successfully.

Details

Journal of Manufacturing Technology Management, vol. 22 no. 6
Type: Research Article
DOI: https://doi.org/10.1108/17410381111149666
ISSN: 1741-038X

Keywords

  • Self Organizing Map
  • Decision trees
  • Artificial neural nets

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Article
Publication date: 1 July 2019

Selection of WEDM parameters to measure the performance and productivity of die steel grade D3 using GRA and fuzzy logic system

Sandeep Kumar and Dhanabalan S.

The purpose of this paper is to examine the performance parameters of WEDM to improve the productivity and material removal rate (MRR) with a high surface finish of high…

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Abstract

Purpose

The purpose of this paper is to examine the performance parameters of WEDM to improve the productivity and material removal rate (MRR) with a high surface finish of high chromium-high carbon dies steel.

Design/methodology/approach

The experiments were performed on AGIE CUT 220 CNC WEDM. High chromium-high carbon dies steel (D3) was used in the form of a rectangular plate. The workpiece and the brass wire having diameter ɸ 0.25 mm had linked up with +ve and –ve polarity in the DC power source, respectively. De-ionized water having a conductivity level of 0.6 µs/cm was used as the dielectric medium. The dielectric fluid was flushed from the top and bottom nozzles and material was submerged in the dielectric.

Findings

The WEDM process parameters for D3 die steel had optimized by using Grey relational analysis method couples with Taguchi method. The optimum solution has been calculated for MRR, cutting speed (Cs), machining time and surface roughness (SR) (Ra value). A fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, cutting speed (Cs), machining time (M/c time) and SR with respect to changes in input parameters.

Research limitations/implications

The fuzzy model shows the 96.19 percent accuracy between the experimental values and the predicted values.

Practical implications

The optimized parameters by multi-parametric optimization method showed considerable improvement in the process and will facilitate the WEDM, tool and die industries, defense and aerospace industries to improve the productivity with the higher surface finish.

Originality/value

This manuscript represents valid work and the authors have no conflict of interests. The attained optimum outcomes had also been examined through a real experiment and established to be satisfactory.

Details

Grey Systems: Theory and Application, vol. 9 no. 3
Type: Research Article
DOI: https://doi.org/10.1108/GS-01-2019-0004
ISSN: 2043-9377

Keywords

  • Cutting speed (Cs)
  • Fuzzy logic
  • Grey relational method (GRA)
  • High chromium-high carbon dies steel (D3)
  • Material removal rate (MRR)
  • Multi-objective optimization
  • Surface roughness (Ra value)
  • Wire-electro discharge machining (WEDM)

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