Prediction and optimization of surface roughness and micro-hardness using grnn and MOORA-fuzzy-a MCDM approach for nitinol in WEDM

Investigation of material removal rate and surface roughness during wire electrical discharge machining (WEDM) of Inconel 625 super alloy by cryogenic treated tool electrode

WEDM process variables investigation for HSLA by response surface methodology and genetic algorithm

Analysis of Response Variables in WEDM of Inconel 718 Using Taguchi Technique

In this research, Wire Electrical Discharge Machining (WEDM) of Nimonic-75 alloy is presented to explore the significance of machining parameters such as pulse-on time, servo voltage, pulse-off time, peak current, wire feed rate and cable tension on performance features such as surface roughness (SR), overcut and metal removal rate (MRR). Experiments are performed according to Taguchi’s L27 orthogonal collection. Principal component analysis is utilized for the optimization of machining parameters. The optimal settings of the machining variables obtained are pulse-on time 110 µs, pulse-off time 51 µs, servo voltage 40 volts, peak current 230 Amp., wire feed rate 5 m/min and cable tension 8 gram. Results of Analysis of Variance (ANOVA) reveal that pulse-on time (contributing 52.90%) is the major influencing factor affecting the performance characteristics. Results of the confirmation experiments indicate that the optimal machining parameters improved the value of composite primary component (CPC) from 1.2013 to 1.2443 for the multiple responses. Scanning Electron Microscopic (SEM) analysis is carried out to examine the microstructure of the machined surfaces.

Optimization of machining parameters of WEDM for Nimonic-75 alloy using principal component analysis integrated with Taguchi method

Investigation of surface integrity, material removal rate and wire wear ratio for WEDM of Nimonic 80A alloy using GRA and Taguchi method

Optimization in wire-cut EDM of Nimonic-80A using Taguchi's approach and utility concept

This work aims to optimize the formability and surface roughness of parts formed by the single-point incremental forming process for an Aluminium-6063 alloy. The tests are based on Taguchi’s L18 orthogonal array selected on the basis of DOF. The tests have been carried out on vertical machining center (DMC70V); using CAD/CAM software (SolidWorks V5/MasterCAM). Two levels of tool radius, three levels of sheet thickness, step size, tool rotational speed, feed rate and lubrication have been considered as the input process parameters. Wall angle and surface roughness have been considered process responses. The influential process parameters for the formability and surface roughness have been identified with the help of statistical tool (response table, main effect plot and ANOVA). The parameter that has the utmost influence on formability and surface roughness is lubrication. In the case of formability, lubrication followed by the tool rotational speed, feed rate, sheet thickness, step size and tool radius have the influence in descending order. Whereas in surface roughness, lubrication followed by feed rate, step size, tool radius, sheet thickness and tool rotational speed have the influence in descending order. The predicted optimal values for the wall angle and surface roughness are found to be 88.29° and 1.03225 µm. The confirmation experiments were conducted thrice and the value of wall angle and surface roughness were found to be 85.76° and 1.15 µm respectively.

Process Parameters Optimization in Single Point Incremental Forming

Trim cut machining and surface integrity analysis of Nimonic 80A alloy using wire cut EDM

Wire Electrical Discharge machining (WEDM) is very complex process due to the presence of large number of process variables involved. WEDM is used for machining of hard material parts that are extremely difficult to machine by conventional machining process. The present work investigates the influence of machining parameters on material removal rate (MRR) and cutting speed (CS) for machining of Nimonic 80A using wire-cut electrical discharge machining (WEDM) process. Two important process responses MRR and CS have been studied as a function of four different control parameters namely Pulse-on time (Ton), Pulse-off time (Toff), Input current (IP) and servo gap set voltage (SV). It was found that that and metal removal rate (MRR) and cutting speed (CS) increases with increase in Ton and IP while decreases with increase in Toff and SV. Experimentation was planned using "one factor at a time approach". WEDM is an electro thermal process in which metal is eroded from the workpiece using a series of sparks generated by a thin wire electrode in the presence of dielectric. WEDM can easily machine any conductive metal irrespective of their hardness. Wire-cut EDM process generates a large amount of heating at the machining area which results in melting and vaporization of metal from localized area. The dielectric is fed continuously to the machining area to flush away the eroded particles (Mahapatra and Patnaik, 2007). Figure 1 shows the schematic representation of the WEDM.

Amitesh Goswami

Papers

Investigation of surface integrity, material removal rate and wire wear ratio for WEDM of Nimonic 80A alloy using GRA and Taguchi method

Optimization in wire-cut EDM of Nimonic-80A using Taguchi's approach and utility concept

Process Parameters Optimization in Single Point Incremental Forming

Trim cut machining and surface integrity analysis of Nimonic 80A alloy using wire cut EDM

Study of machining characteristics of Nimonic 80A using wire-cut EDM