Journal articles: 'Electric discharge wire cutting'

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Sugimoto, Tatsunori, Toshiya Noro, Satarou Yamaguchi, Hideyoshi Majima, and Tomohisa Kato. "Spectroscopic Measurement of Electric Discharge Machining for Silicon Carbide." Materials Science Forum 615-617 (March 2009): 609–12. http://dx.doi.org/10.4028/www.scientific.net/msf.615-617.609.

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Diamond saw is generally used to make the silicon carbide (SiC) wafers from ingots, but it takes long time for cutting. We have used the electric discharge machining (EDM) to cut SiC. The cutting speed of EDM for SiC is almost 10 times faster than the diamond saw, and the surface roughness is 1/10 for the diamond saw. EDM cut SiC by the plasma produced between the wire and SiC material. The emissions from EDM plasma may involve much information for EDM cutting. We monitored the total light intensity by a photodiode, and observed the spectrum of the emission from EDM plasma by a visible spectroscopy. The discharge gas used helium and argon. In both discharges, the light emission was observed when the current was not zero. Also, many lines were observed Si I, Si II and C I from the SiC sample, and Cu I and Zn I from the wire. And, the electron temperature of EDM plasma was estimated to be under several eV because the observed lines were almost the emission from atoms. Also, the scars, which show the copper-alloy wire was hurt by discharge, were observed from the wire.

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Yamada, Hideki, Satarou Yamaguchi, Norimasa Yamamoto, and Tomohisa Kato. "Cutting Speed of Electric Discharge Machining for SiC Ingot." Materials Science Forum 717-720 (May 2012): 861–64. http://dx.doi.org/10.4028/www.scientific.net/msf.717-720.861.

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A new method based on electric discharge machining (EDM) was developed for cutting a silicon carbide (SiC) ingot. The EDM method is a very useful technique to cut hard materials like SiC. By cutting with the EDM method, kerf loss and roughness of sample are generally smaller than those obtained by cutting with a diamond saw. Moreover, the warpage is smaller than that by the diamond saw cutting, and the cutting speed can be 10 times faster than that of the diamond saw at the present time. We used wires of 50 mm and 100 mm diameters in the experiments, and the experimental results of the cutting speed and the kerf losses are presented. The kerf loss of the 50 mm wire is less than 100 mm, and the cutting speed is about 0.8 mm/min for the thickness of a 6 mm SiC ingot. If we can maintain the cutting speed, the slicing time of a 2 inches diameter ingot would be about seven hours.

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Wang, Jing, and Ming Gui Zhou. "Processing Stability Analysis of Wire Cut Electric Discharge Machine with High Speed." Applied Mechanics and Materials 443 (October 2013): 74–78. http://dx.doi.org/10.4028/www.scientific.net/amm.443.74.

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In this article, unstable factor analysis is done in Wire cut electric discharge machine with high speed (WEDM HS), which focus on effect of processing Stability from electrical processing parameters, machine parameters, electrode wire, cutting fluid and conductive block, and how to adjust and excluding factors in order to enhance WEDM processing stability ,ensure machine parts surface quality, dimensional accuracy and processing efficiency.

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Yamamoto, Norimasa, Satarou Yamaguchi, and Tomohisa Kato. "Slicing of Rotating SiC Ingot by Electric Discharge Machining." Materials Science Forum 740-742 (January 2013): 843–46. http://dx.doi.org/10.4028/www.scientific.net/msf.740-742.843.

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A new method of electric discharge machining (EDM) is proposed for slicing a large silicon carbide (SiC) ingot in order to realize low kerf loss and fast cut. This principle is based on the rotating ingot, and it is called the rotating slicing method (RSM). It would be defecate the cutting chip effectively and one-point discharge. In this paper, we reported results of examinations of the RSM experimentally. Unstable discharge was not observed. Discharge damages on the wire surface were fewer than those of the conventional method. Net cutting speed was almost the same as the present method for the 2-inches ingot. The rotation axis of the ingot should be perpendicular to the feed direction of the wire, and it is important to fix the performance of the EDM such as the kerf loss. Roughness of the cutting surface was 3.4 µm of Ra

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Beaucamp, Anthony T. H., and Yoshimi Takeuchi. "Reverse Engineering Algorithm for Cutting of Ruled Geometries by Wire." International Journal of Automation Technology 16, no. 3 (May 5, 2022): 349–55. http://dx.doi.org/10.20965/ijat.2022.p0349.

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Abrasive wire cutting (AWC) and wire electric discharge machining (WEDM) are efficient and economical processes for the fabrication of precision parts from bulk material. Operating costs and manufacturing lead times are low compared to more general methods such as 5-axis CNC milling, turning, or electro-discharge machining. In this paper, an algorithm based on differential geometry in Euclidean space is proposed for reverse engineering of ruled geometries. The algorithm can determine whether a given geometry is producible by wire cutting, and can also derive the associated wire trajectories. Implementation is demonstrated by producing complex turbine blade geometries on 4-axis wire cutting machines with an overall shape accuracy of 20–40 μm peak-to-valley.

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Xin, Bin, and Wei Liu. "Experimental Research on Discharge Forming Cutting-Electrochemical Machining of Single-Crystal Silicon." Mathematical Problems in Engineering 2021 (August 4, 2021): 1–13. http://dx.doi.org/10.1155/2021/6024662.

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During the wire electrical discharge machining (WEDM) process, a large number of discharge pits and a recast layer are easily generated on the workpiece surface, resulting in high surface roughness. A discharge forming cutting-electrochemical machining method for fabricating single-crystal silicon is proposed in this study to solve this problem. On the same processing equipment, single-crystal silicon is first cut using the discharge forming cutting method. Second, electrochemical anodic reaction technology is used to dissolve the discharge pits and recast layer on the single-crystal silicon surface. The machining mechanism of this process, the surface elements of the processed single-crystal silicon and a comparison of the kerf width are analyzed through experiments. On this basis, the influence of the movement speed of the copper foil electrode during electrochemical anodic dissolution on the final surface roughness is qualitatively analyzed. The experimental results show that discharge forming cutting-electrochemical machining can effectively eliminate the electrical discharge pits and recast layer, which are caused by electric discharge cutting, on the surface of single-crystal silicon, thereby reducing the surface roughness of the workpiece.

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Okik Aris, Setiawan, Djumhariyanto Dwi, and Mulyadi Santoso. "OPTIMASI PARAMETER PEMESINAN WIRE ELECTRIC DISCHARGE MACHINING BAJA PERKAKAS SKD 11 MENGGUNAKAN METODE TAGUCHI." ROTOR 11, no. 2 (November 1, 2018): 33. http://dx.doi.org/10.19184/rotor.v11i2.9647.

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EDM wire is one of the non-conventional machinings that is currently widely used in the manufacturing industry because it can process workpieces with hard material and also produces excellent dimensional accuracy. This research was carried out with variable current, voltage and wire speed processes. While the response variable is the material removal rate and cutting width (kerf), this study aims to determine the effect of each factor on each response as well as on the combined response and to find the right combination of parameters to produce optimal response values. The results of the study stated that the current strong factor contributed 89.84% and the wire speed factor was 8.26% against the cutting width response (kerf). The current strong element contributes 87.88% to the material removal rate response. As for the combined response, the influential factor was wire speed with a contribution of 92.79%. The optimal combination of parameters in the combined response is 7 amperes, 5 volts and 10 m / s wire speed. The conclusion of this study informs that the smaller the current strength, the better the value of the cutting width, while the more significant the current force will result in a higher removal rate material. The factor that influences the combined response is wire speed, where the increase in the value of the wire speed increases the amount of the Gray Relational Grade from the combined response. Keywords: Wire EDM, SKD 11 Steel, Taguchi, Optimization

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Venkatarao, K., and T. Anup Kumar. "An experimental parametric analysis on performance characteristics in wire electric discharge machining of Inconel 718." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 14 (April 4, 2019): 4836–49. http://dx.doi.org/10.1177/0954406219840677.

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Wire cut electrical discharge machining was identified as a good alternative to conventional machining for machining super alloys that possess low machinability. In the present work, effect of wire tension along with current, pulse on time, and pulse off time on the performance characteristics such as spark gap, surface roughness, amplitude of wire vibration, and cutting rate were studied in wire cut electrical discharge machining of Inconel 718 metal. Experiments were conducted at five levels of the process parameters as per orthogonal array of L25 and their results were collected. These experimental results were analyzed and the interaction effect of wire tension along with current, pulse on time, and pulse off time on performance characteristics was studied using analysis of variance. Response models were developed for the four responses in terms of process parameters and the accuracy of such models was tested. In addition to the above studies, effect of the wire displacement on the kerf size, cutting rate was studied. Spark energy was also estimated for all the experiments and its effect on the performance characteristics was studied. The response models developed in this study were able to predict the experimental results i.e. amplitude of wire vibration, surface roughness, cutting rate, and spark gap with an accuracy of R2 values of 1.0, 0.96, 0.88, and 0.99, respectively. Interaction effect of current and wire tension was found to have the most significant effect on the amplitude of cutter vibration and surface roughness.

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Shandilya, Pragya, Arun Kumar Rouniyar, and D. Saikiran. "Multi-objective parametric optimization on machining of Inconel-825 using wire electrical discharge machining." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 234, no. 20 (April 15, 2020): 4056–68. http://dx.doi.org/10.1177/0954406220917706.

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Wire electrical discharge machining is a thermal energy-based non-conventional machining process which can machine conductive materials with high precision. In this present work, machining of Inconel-825 was performed using wire electrical discharge machining. Multi-objective parametric optimization was performed for maximum cutting rate and minimum surface roughness using teaching–learning-based optimization, grey relational analysis, and genetic algorithm. Four wire electrical discharge machining parameters, namely spark off time (SOFF), spark on time (SON), peak current (IP), and angle of cutting (A) were considered. Comparison of optimum wire electrical discharge machining parameters through teaching–learning-based optimization, grey relational analysis, and genetic algorithm was performed. The better optimum solution for wire electrical discharge machining parameters was obtained using teaching–learning-based optimization and optimum values were at IP (1 A), SON (30 µs), SOFF (12.5 µs), and A (44.8°) with cutting rate as 19.744 mm/min and surface roughness as 1.331 µm. The optimum results obtained using optimization techniques were validated with the experimental results and error was observed to be within 5%. Moreover, response surface models were developed to predict the cutting rate and surface roughness in terms of wire electrical discharge machining parameters using analysis of variance.

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Hosseini, S. B., Uta Klement, and J. Kaminski. "Microstructure Characterization of White Layer Formed by Hard Turning and Wire Electric Discharge Machining in High Carbon Steel (AISI 52100)." Advanced Materials Research 409 (November 2011): 684–89. http://dx.doi.org/10.4028/www.scientific.net/amr.409.684.

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White layers, formed during hard turning and wire electric discharge machining, were characterized by means of X-ray diffraction, scanning electron microscopy and transmission electron microscopy. Different cutting speeds and flank wear were utilized in order to obtain different thermally and/or plastically deformed white layer. Since the white layer after wire electric discharge machining is mainly thermally induced, it was used as a reference structure. In the investigation, both bainitic and martensitic structures were studied. With a constant flank wear of 0.175 mm the thickness of the white layer increased from 1.5 μm to 3 μm as the cutting speed was increased. In both processes the white layer were characterized by nanosized grains and surface tensile residual stresses. M3C carbides were observed in the hard turned white layer, indicating that the time and temperature needed for completely dissolving the carbides were not reached during cutting. For both materials the white layers formed by wire electric discharge machining consisted of ~ 30 vol. % of retained austenite. Observation regarding the volume fraction of the retained austenite in the white layer formed by hard turning for martensitic material showed an increase in the volume fraction of retained austenite from ~ 2 - 3 vol. % to ~ 6 vol. %, while this observation was not seen in the white layer formed in the bainitic material.

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Durairaj, M., A. K. S. Ansari, and M. H. Gauthamkumar. "Parametric optimization of wire cut electrical discharge machining." International Journal of Engineering & Technology 3, no. 2 (April 26, 2014): 212. http://dx.doi.org/10.14419/ijet.v3i2.1807.

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Wire Electrical Discharge Machining is a manufacturing process whereby a desired shape is obtained using electrical discharges (or) by repetitive spark cycle. Precision and intricate machining are the strengths. Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements. Selection of optimum machining and machining parameters combinations is needed for obtaining higher cutting efficiency and accuracy. In this present study, machining is done using Wire-Cut EDM and optimization of surface roughness is done using Taguchis design of experiments. Experimentation was planned as per Taguchis L16 orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, and pulse OFF time and Wire feed. Dielectric fluid pressure, wire speed, wire tension, resistance and cutting length are taken as fixed parameters. Inconel 800 was selected as a work material to conduct the experiments. From experimental results, the surface roughness was determined for each machining performance criteria. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method. Keywords: Optimization; Taguchis L-16 Orthogonal Array; Surface Roughness; S/N Ratio.

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CHE NOR, Che Muhamad Hamzah, Mohd Shahir KASIM, Effendi MOHAMAD, Mohd Amri SULAIMAN, and Teruaki ITO. "2314 Study on cutting parameter on kerf width using wire electrical discharge machining of Inconel 718." Proceedings of Design & Systems Conference 2014.24 (2014): _2314–1_—_2314–6_. http://dx.doi.org/10.1299/jsmedsd.2014.24._2314-1_.

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Muthuraman, Veluswamy, Raju Ramakrishnan, Ponnusamy Sengottuvel, and C. Karthikeyan. "Experimental Study and Optimization of Wire-Electrical Discharge Machined WC-15%Co Metal Matrix Composites." Advanced Materials Research 984-985 (July 2014): 227–32. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.227.

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Wire Electrical discharge Machining plays an important role in the field of hard, difficult to machine materials like metal matrix composites. Machining process must keep pace with material development. For electrically conductive materials wire electro discharge machining is a viable option due to high accuracy, precision, and ability to achieve complex, intricate shaped profiles on even thin works. Due to thermo-electric nature it is a stochastic process in nature. To simplify the difficulty in determining parameters for the improvement of cutting performance and optimization, analysis of variance and regression analysis were made use of. Tungsten carbide cobalt metal matrix composites finds increasing applications in conventional application like tools and dies as well as in developing fields like bio-medical instruments and aero-space industries. In this present work, the problem of parameter selection, optimization for wire electro discharge machining on tungsten carbide-15% cobalt metal matrix composites, a less worked composition has been undertaken. Sodick AQ-427L wire-edm machine was used with a 0.25 diameter zinc coated brass wire electrode, to cut the material. Each experiment done under different cutting conditions of inputs like pulse on time, pulse off time, wire speed and peak current and repeated for three observations and the average was selected. Optimum machining parameter combination for material removal rate was obtained by using the desirability response optimizer function. Analysis of variance, Confirmation experiment was carried and good improvements were obtained.

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Shandilya, Pragya, N. K. Jain, and P. K. Jain. "Experimental Studies on Wire Electric Discharge Cutting of SiC_p/6061 Aluminum Metal Matrix Composites." Key Engineering Materials 450 (November 2010): 173–76. http://dx.doi.org/10.4028/www.scientific.net/kem.450.173.

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This paper reports about the experimental findings on the wire electric discharge cutting (WEDC) of 6061 aluminum metal matrix composite (MMC) reinforced with silicon carbide particulates (i.e. SiCp/6061 Al). Four WEDC parameters namely servo voltage, pulse-on time, pulse-off time and wire feed rate were varied to study their effect on the quality of cut in SiCp/6061 aluminum MMC using average cutting rate and microstructure of the cut surface as response parameters. The experiments were conducted using one-factor-at-a-time experiment strategy in which only one input parameter was varied while keeping all other input parameters as constant. The experimental results indicate that the average cutting speed is mainly affected by pulse-on time, pulse-off time, and voltage and the changes are more prominent for the MMC 7.5% SiCp. The characteristics of the surface produced by WEDC were analyzed by scanning electron microscopy (SEM). Analysis of SEM images of the cut surface has revealed that the depth of micro-voids and micro-cracks slightly increases as the voltage and pulse-on time increases and as pulse-off time and wire feed rate decreases. there seems to be trade-off between the average cutting speed and better quality of cut for Al-SiCp MMC as far the values of pulse-on time, pulse-off time are considered and final choice will depend upon the type of application. An optimum range of the input parameters has been bracketed as the final outcome of this work for carrying out further research to develop the models for WEDC of SiCp/6061 aluminum MMC and to optimize the WEDC parameters for the best quality of cut and to minimize the wire breakage frequency.

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Saedon, J. B., Norkamal Jaafar, and Mohd Azman Yahaya. "Characteristics of Machining Parameters on WEDM Titanium Alloy." Materials Science Forum 872 (September 2016): 23–27. http://dx.doi.org/10.4028/www.scientific.net/msf.872.23.

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Wire electrical discharge machining is a material removal process of electrically conductive materials by the thermo-electric source of energy. This kind of machining extensively used in machining of materials with highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using wire electro-discharge machining with brass wire diameter 0.5mm.The objective of this work is to study the influence of three machining parameters namely peak current, pulse off time and wire tension to cutting rate, material removal rate, surface roughness and kerf width followed by suggesting the best operating parameters towards good machining characteristics. A full factorial experimental design was used with variation of peak current, feed rate and wire tension, with results evaluated using analysis of variance techniques. Parameter levels were chosen based on best practice and results from preliminary testing. Main effects plots and percentage contribution ratios are included for the main factors and their interactions.

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Luo, Hong Ping, Zhi Xiong Zhou, Yong Jun Zhang, and Zhong Ning Guo. "Wire Electrical Discharge Machining (Wire EDM) Cutting of Flexures for a Rotary Flexural Bearing Fabrication." Advanced Materials Research 314-316 (August 2011): 1727–33. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.1727.

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Wire electrical discharge machining (Wire EDM) cutting of flexures for a rotary flexural bearing fabrication is developed. The results of FEA calculation and theoretical analysis show that one of the main factors affecting flexures’ machining is the weak torsional stiffness of the bearing cage, thus excessive deflections due to machining stress, heat generation and spark-induced vibrations may occur. To minimize flexure deflection during the machining process, a specially designed fixture is utilized. Other technical measures, including residual stress relief before and after Wire EDM cutting, reasonable cutting sequence planning, multiple-cutting (i.e., rough cut followed by several trim cuts) etc., are also adopted for cutting. Dimensional accuracy of ±5µm was obtained over the 150µm thickness for the bearing flexures, a variation of less than 3µm was achieved for the flexures of opposing sides, and surface roughness of better than Ra 0.3μm was obtained for the flexures of the entire bearing cage. These results show the validity of measures aforementioned.

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Saedon, J. B., Norkamal Jaafar, Roseleena Jaafar, Nor Hayati Saad, and Mohd Shahir Kasim. "Modeling and Influence of Machining Parameters on Titanium Aloy." Advanced Materials Research 911 (March 2014): 220–25. http://dx.doi.org/10.4028/www.scientific.net/amr.911.220.

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Wire electrical discharge machining (WEDM) is a material removal process of electrically conductive materials by the thermo-electric source of energy which is extensively used in machining of materials for a highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using WEDM with a brass wire diameter of 0.25mm.The objective of this work is to study the influence of three machining parameters, namely peak current (IP), feed rate (FC) and wire tension (WT) to cutting speed and surface roughness as a responses. Response Surface Methodology was used to develop second order model in order to predict cutting speed and surface roughness responses. The results showed that the average percentage error between the predicted and experimental value for both models was less than 2%. Effects of each parameter and their interaction with percentage contribution ratios (PCR) are included for each response.

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Zhang, Li Xin, and Li Hui Wang. "Quality Research on Electric Discharge Machining with Rotary Surface of Engineering Ceramic." Advanced Materials Research 602-604 (December 2012): 2002–5. http://dx.doi.org/10.4028/www.scientific.net/amr.602-604.2002.

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This paper introduces the theoretical basis and function of developing spindle rotary device. A technological method of wire electro-discharge grinding(WEDG),which is based on the wire electrode cutting machine, is presented. The main factors that influence the machining of engineering ceramic material surface quality are analyzed. And the conclusion is that there are main factors: the main structure and conductivity of the spindle rotary device, and the changes of power in the process of single pulse machining discharge. The conclusions from the experiments provide the theoretical basis for further study on the factors that influence the rotary workpiece surface quality and for the discussion on methods of improving the rotary workpiece surface quality; the conclusions also expand the process scope of WEDM.

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Bokov, Victor, Oleh Sisa, and Vasyl Yuryev. "Improving Electrical Discharge Machining Process for Bodies of Rotation." Central Ukrainian Scientific Bulletin. Technical Sciences, no. 3(34) (October 2020): 313–24. http://dx.doi.org/10.32515/2664-262x.2020.3(34).313-324.

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In modern mechanical engineering, electrical discharge machining (EDM) methods are widely used for machining bodies of rotation from difficult-to-machine materials. Those methods ensure sparing cutting and make it possible to machine any electrically conductive material irrespective of its physical and chemical properties, in particular hardness. There is a known method for dimensional machining of bodies of rotation with electric arc using a wire electrode tool that is pulled along in the machining area thus "compensating" for that tool's EDM wear and tear. The machining accuracy is therefore significantly heightened. However, when implementing this method, an effect of splashing the working fluid outside the working area of the machine and a pronounced luminous effect from the burning of the electric arc in the machining area are observed. That worsens the working conditions. In addition, when pulling the wire electrode tool along the convex surface of the electrode holder, the sliding friction arises, which eventually leads to mechanical destruction of the contact point. As a result, a deep kerf is formed on the electrode holder. When the depth of the kerf reaches the diameter of the wire electrode tool, the destruction of the electrode holder by the electric arc begins. Consequently, the durability of the electrode holder in the known method is unsatisfactory. A method of dimensional machining of bodies of rotation with electric arc using a wire electrode tool with the immersion of the machining area in the working fluid has been proposed, which makes it possible to improve the working conditions of the operator by eliminating the effect of fluid splashing and removing the luminous effect of arc burning in the machining area. In addition, it has been proposed to make the electrode holder in the form of a roller that rotates with a guide groove for the wire electrode tool, while the nozzle for creating the transverse hydrodynamic fluid flow has been proposed to be mounted in a separate fixed housing that is adjacent to the electrode holder. This technical solution replaces the sliding friction with the rolling one thus enhancing the durability of the electrode holder. Mathematical models of the process characteristics of the DMA-process (dimensional machining with electric arc) for bodies of rotation using a wire electrode tool with the immersion of the machining area in the working fluid have been obtained that make it possible to control the machining productivity, the specific machining productivity, the specific electric power consumption, and the roughness of the surface machined.

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Bisaria, Himanshu, and Pragya Shandilya. "The machining characteristics and surface integrity of Ni-rich NiTi shape memory alloy using wire electric discharge machining." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 233, no. 3 (March 26, 2018): 1068–78. http://dx.doi.org/10.1177/0954406218763447.

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Owing to the increasing demand for Ni-rich shape memory alloys in various sectors such as biomedical, aerospace, and robotics, the efficient machining of shape memory alloys is vital for their productive exploitation. The aim of this experimental investigation is to explore the influence of wire electric discharge machining process parameters such as spark gap voltage, wire tension, spark off time, wire speed, and spark on time, on the cutting efficiency and surface roughness of Ni50.89Ti49.11 SMA using one factor at a time approach. The results reveal that cutting efficiency and surface roughness are strongly influenced by spark off time, spark on time, and spark gap voltage, whereas wire speed and wire tension have the inconsequential effect. The presence of many microcracks, craters, voids, bulges of debris, and the re-solidified layer of molten material on the machined surface have been detected in scanning electron micrographs. The results of phase analysis using energy-dispersive X-ray spectroscopy and X-ray diffraction divulge the migration of foreign elements from the brass wire and dielectric to the machined surface. Due to the formation of recast layer and various oxides, the hardening effect near the machined surface was also observed. The hardness near the machined surface has been increased several times in comparison to bulk hardness.

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Dodun, Oana, Vasile Merticaru, Laurenţiu Slatineanu, and Margareta Coteaţă. "Optimization of the Wire Electrical Discharge Machining Process Using Grey Relational Analysis and Taguchi Method." Key Engineering Materials 651-653 (July 2015): 738–43. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.738.

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The wire electrical discharge machining is a machining method able to allow detaching parts from plates type workpieces as a consequence of electrical discharges developed between workpiece and wire tool electrode found in a motion along its axis; there is also a work motion along the contour to be obtained. There are many factors able to exert influence on the sizes of parameters of technological interest. On the other hand, there are various methods that can be used in order to establish the optimal combination of the input factors, so that obtaining of machining best results is possible. When there are many process output factors, a problem of multiobjective optimization could be formulated. The Grey relational analysis method and the Taguchi method could be applied in order to optimize the wire electrical discharge machining process, when various criteria having distinct significances are considered. An experimental research was designed and developed in order to optimize the wire electrical discharge cutting of parts made of an alloyed steel, by considering six input factors: test piece thickness, pulse on time, pulse off time, wire axial tensile, current intensity and travelling wire electrode speed. As output parameters, one took into consideration surface roughness, wire tool electrode massic wear, cutting speed along the contour to be obtained. 16 experiments were developed in accordance with the requirements specific to a Taguchi table L16. The results of experiments were processed by means of Grey relational analysis method and Taguchi method.

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Guo, Li Bin, Hai Cui, Bin Zhang, and Zhi Hang Zhang. "Research on Statistical Parameters of 3-D Roughness for Micro Wire Electric Discharge Machining Surface." Key Engineering Materials 572 (September 2013): 287–90. http://dx.doi.org/10.4028/www.scientific.net/kem.572.287.

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Amplitude parameters and functional parameters of three-dimensionalroughness are established by statistics geometry. Since micro wire electric discharge machining (MWEDM) surface approximately follows the Gauss distribution, its statistical characteristics are different from cutting processing surface. Characterization meaning between MWEDM surface and cutting processing surface is rather different. This study begins with shape parameters’ mathematics essence of surface height distribution of three-dimensionalroughness, analyzes their definite characterization meanings for MWEDM surface, deeply researches bearing ratio curve of MWEDM surface, reasonably ascertains its functional areas and finally establishes nine functional parameters where volume parameter is the main one.

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Sharma, Neeraj, Tilak Raj, and Kamal Kumar Jangra. "Parameter optimization and experimental study on wire electrical discharge machining of porous Ni40Ti60 alloy." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 6 (March 31, 2015): 956–70. http://dx.doi.org/10.1177/0954405415577710.

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NiTi is a shape memory alloy, mostly employed in cardiovascular stents, orthopedic implants, orthodontic wires, micro-electromechanical systems and so on. The effective and net shape machining of NiTi is very critical for excellent response of this material in medical and other applications. The present experimental work on wire electrical discharge machining process identifies the influence of process parameters that affect the cutting rate, dimensional shift and surface roughness while machining of porous nickel–titanium (Ni40Ti60) alloy. Porous Ni40Ti60 alloy was produced in-house using powder metallurgy technique. Response surface methodology–based central composite rotatable design has been used for the planning of experiments on wire electrical discharge machining. Empirical relations have been developed between the process parameters (pulse on-time, pulse off-time, servo voltage and peak current) and response variables. Desirability approach has been used for optimizing the three response variables simultaneously. Confirmation experiments were also performed at the optimized settings and reflect a close agreement between the predicted and experimental values (percentage error varies from −6.13% to +6.85%). Using wire electrical discharge machining, NiTi alloy can be machined easily and successfully in single-cutting operation, but after the first cut in wire electrical discharge machining, a surface projection appears on work surface which is the unmachined material on work surface.

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Furutani, Katsushi. "Proposal for Abrasive Layer Fabrication on Thin Wire by Electrical Discharge Machining." International Journal of Automation Technology 4, no. 4 (July 5, 2010): 394–98. http://dx.doi.org/10.20965/ijat.2010.p0394.

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This paper deals with a method of fabricating an abrasive layer on a thin wire by means of electrical discharge machining (EDM). An electrodeposited wire saw is useful for slicing a silicon ingot. However, strong acids are used in the production process and the depositing speed is slow. To overcome these problems, a fabrication process for an abrasive layer on a thin wire by EDM is proposed. The layer deposited by EDM with a green compact electrode is porous under certain electrical conditions so that the layer is composed of abrasive grit, pores and bond. A mixture of WC, Co, and the abrasive was compressed to make the green compact electrode. Two green compact electrodes were placed facing each other and were reciprocally fed during the process. The WC layer was deposited in 1s on an area in a preliminary experiment. The feed rate of 0.12-mm piano wire was set to 50mm/min. Al2O3abrasive powders with a size of 35-50µm were able to be contained in the WC layer on the wire. The deposit containing the abrasive firmly adhered. Because the deposited WC layer was very hard, tight gripping of the grit can be also expected. A copper block was cut with a raw piano wire, with wires with or without the abrasive deposited by EDM, and with electrodeposited or resinoid wire saws available on the market to compare their cutting performance. The initial tension was set to 5N and the cutting load was changed from 5.5 to 9.0N. The average feed speed of the wire was set to 8m/min. After 2000 reciprocating motions, the amounts machined with the deposited wire were larger than those with the wire saw available on the market. The deposited wire endured the same cutting load as the electrodeposited wire saw.

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Bosoancă, Gheorghe, Laurenţiu Slătineanu, Margareta Coteaţă, and Ana Badanac. "Application of the Ideas Diagram Method for Device Design in Wire Electrical Discharge Machining." Applied Mechanics and Materials 809-810 (November 2015): 393–98. http://dx.doi.org/10.4028/www.scientific.net/amm.809-810.393.

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Wire electrical discharge machining is nowadays applied by using adequate specialized machine tools. A research problem could refer to a device for wire electrical discharge machining, adaptable on the current computer numerical controlled ram electrical discharge machines. The device could be able to be used in order to develop cutting processes in plate type workpieces. The wire electrical discharge machining process was examined and premises for developing a device for wire electrical discharge machining were formulated. These premises are used in order to develop an ideas diagram able to offer suggestions for the structure of the device. Distinct components necessary in the device structure were identified and taken into consideration, and three distinct versions of the device were defined.

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Ishfaq, Kashif, Nadeem Ahmad Mufti, Mohammad Pervez Mughal, Muhammad Qaiser Saleem, and Naveed Ahmed. "Investigation of wire electric discharge machining of stainless-clad steel for optimization of cutting speed." International Journal of Advanced Manufacturing Technology 96, no. 1-4 (February 13, 2018): 1429–43. http://dx.doi.org/10.1007/s00170-018-1630-9.

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Ramulu, Mamidala, Mathew Spaulding, and P. Laxminarayana. "Cutting Characteristics of Titanium Graphite Composite by Wire Electrical Discharge Machining." Advanced Materials Research 630 (December 2012): 114–20. http://dx.doi.org/10.4028/www.scientific.net/amr.630.114.

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To improve strength to weight ratios, the fiber reinforced polymer composite materials are often used in conjunction with another material, like metals, to form hybrid structure. This paper reports the feasibility of using wire electrical discharge machining (WEDM) for cutting Titanium/Graphite Hybrid Composites (TiGr). Slit and slot cuts with WEDM process has been performed. Cutting times and process parameters were recorded, and cut surface characteristics were evaluated both with an optical and scanning electron microscopy (SEM). The results in terms of cutting time, workpiece material removal rate, and damage were presented and discussed. It was found that use of WEDM is possible for machining advanced hybrid metal composite laminates with appropriate machine settings.

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Shukla, Rahul, and Brajesh Kumar Lodhi. "Experimental Analysis of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Method." Applied Mechanics and Materials 799-800 (October 2015): 343–50. http://dx.doi.org/10.4028/www.scientific.net/amm.799-800.343.

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Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L9 Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (TON), pulse-off-time (TOFF), peak current (IP), and wire feed (WF) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.

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Sharma, Husandeep, Khushdeep Goyal, and Sunil Kumar. "Performance evaluation of cryogenically treated wires during wire electric discharge machining of AISI D3 die tool steel under different cutting environments." Multidiscipline Modeling in Materials and Structures 15, no. 6 (November 4, 2019): 1318–36. http://dx.doi.org/10.1108/mmms-04-2019-0078.

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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.

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Shandilya, Pragya, P. K. Jain, and N. K. Jain. "Study on Wire Electric Discharge Machining Based on Response Surface Methodology and Genetic Algorithm." Advanced Materials Research 622-623 (December 2012): 1280–84. http://dx.doi.org/10.4028/www.scientific.net/amr.622-623.1280.

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Wire electric discharge machining (WEDM) is one of the most popular non-conventional machining processes for machining metal matrix composites (MMCs). The present research work deals the parametric optimization of the input process parameters for response parameter during WEDM of SiCp/6061 Al metal matrix composite (MMC). Response surface methodology (RSM) and genetic algorithm (GA) integrated with each other to optimize the process parameters. RSM has been used to plan and analyze the experiments. Four WEDM parameters namely servo voltage, pulse-on time, pulse-off time and wire feed rate were varied to study their effect on the quality of cut in SiCp/6061 Al MMC using cutting width (kerf) as response parameter. The relationship between kerf and machining parameters has been developed by using RSM. The mathematical model thus than developed was then employed on GA to optimized the process parameters.

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Singh, Kuldeep, Khushdeep Goyal, and Deepak Kumar Goyal. "Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel." Advanced Engineering Forum 28 (June 2018): 55–66. http://dx.doi.org/10.4028/www.scientific.net/aef.28.55.

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In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

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Iwai, Manabu, Shinichi Ninomiya, Tokiteru Ueda, and Kiyoshi Suzuki. "Electrical Discharge Truing of a Vitrified Bonded Superabrasive Wheel with Electrical Conductivity." Advanced Materials Research 591-593 (November 2012): 319–24. http://dx.doi.org/10.4028/www.scientific.net/amr.591-593.319.

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With its high grit retention and easiness to true and dress, the vitrified bond is widely used as a bond material for cBN and diamond grinding wheels. By giving electrical conductivity to the vitrified bond, application of electrical discharge trueing/dressing and detection of a workpiece position by electrical contact sensing will become possible. And moreover, application of the vitrified bonded wheels to various types of electro-assisted grinding processes (electrochemical or electro discharge assisted methods) is expected. In this study, vitrified bonded diamond segments with electrical conductivity were manufactured experimentally by mixing the fine copper powders in the vitrified bond matrix. As a result of investigation into the electro discharge trueing performance in the die sinking and wire electro discharge machining, it was found that a vitrified bonded wheel could be formed by electro discharge machining only because the bond was electrically conductive. In addition, the electro discharge complex grinding utilizing electric discharge machining was applied to the PCD cutting tool materials using the electrically conductive vitrified bonded wheel, and confirmed that the grinding could be continued for a long time maintaining a stable grinding force.

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Saedon, J. B., Norkamal Jaafar, Roseleena Jaafar, Nor Hayati Saad, and Mohd Shahir Kasim. "Modeling and Multi-Response Optimization on WEDM Ti6Al4V." Applied Mechanics and Materials 510 (February 2014): 123–29. http://dx.doi.org/10.4028/www.scientific.net/amm.510.123.

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Wire electrical discharge machining (WEDM) is a material removal process of electrically conductive materials by the thermo-electric source of energy which is extensively used in machining of materials for a highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using WEDM with a brass wire diameter of 0.25mm.The objective of this work is to study the influence of three machining parameters, namely peak current (IP), feed rate (FC) and wire tension (WT) to cutting speed and surface roughness. Response Surface Methodology was used to develop second order model in order to predict cutting rate and surface roughness responses. The results showed that the average percentage error between the predicted and experimental value for both models was less than 2%.Furthermore, the developed models were used for multiple-response optimization by desirability function approach to determine the optimum machining parameters. These optimized machining parameters are validated experimentally, and it is observed that the response values are in good agreement with the predicted values.

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Li, Jian Gang, and Jin Wang. "Research on Wire-Electro Discharge Machining of SiC Particle Reinforced Cu Matrix Composite." Advanced Materials Research 347-353 (October 2011): 1088–92. http://dx.doi.org/10.4028/www.scientific.net/amr.347-353.1088.

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The law of peak current, pulse width and working voltage parameter etc which influencing on wire-electro discharge machining (WEDM) cutting speed and surface roughness of the SiC particle reinforced Cu matrix composite in the WEDM machining were studied; the machined surface of Cu matrix composite was analyzed by means of scanning electron microscope (SEM); SiC Particle reinforced Cu matrix composite microstructure was analyzed by means of metallographic microscope. The results show that the first factors are peak current and pulse width, the second is working voltage. While pulse interval has reached a certain degree, pulse interval has slightly influence on surface roughness. If peak current is higher and pulse width is narrower, the wire electric discharging machining is ideal for matrix composite.

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Durairaj, M., S. Elanthirayan, K. Aanand, and J. Poornachandran. "Optimization of Cutting Parameters in Wirecut EDM of D2 Die Steel Using Gravitational Search Algorithm." Applied Mechanics and Materials 592-594 (July 2014): 591–94. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.591.

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Wire cut Electrical Discharge Machining is one of the important manufacturing process which is used to obtain desired shape using electrical discharge (or) by continuous sparking. This paper deals with wire cut EDM of D2die steel using Zinc coated wire tool. Two conflicting objectives, surface roughness and kerf width, are simultaneously optimized. Experimentation was planned based on Taguchi’s L-9 orthogonal array. All the experiments has been conducted under different machining conditions of gap voltage, pulse ON time, and pulse OFF time. Wire feed, wire speed, resistance, wire tension, dielectric fluid pressure and cutting length are taken as fixed parameters. In this paper Gravitational Search Algorithm (GSA) is employed for optimising surface roughness and kerf width.

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Balasubramanian, I. "A Study on Surface Roughness and Cutting Width for Circular Contour Machining of Stir Cast AA6063/SiC Composites in WEDM." JOURNAL OF ADVANCES IN CHEMISTRY 13, no. 10 (February 25, 2017): 6524–30. http://dx.doi.org/10.24297/jac.v13i10.5829.

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Wire electrical discharge machining is used in machining electric conductive materials with intricate shapes and profiles. This paper presents an experimental investigation on the influence of cutting conditions of WEDM on surface roughness and cutting width of machining of AA6063/SiC composites. Here a semi cylindrical piece is removed from a rectangular plate of AA6063/SiC composites plate fabricated with reinforcing SiC in 0%, 5%, 10% and 15% weight fractions through stir casting. The effect of WEDM parameters such as pulse on time, pulse off time and peak current on surface roughness and cutting width on different composition of AA6063/SiC were analyzed for circular contour machining. The experimental results show that increase in percentage of SiC has high influence in mechanical behavior of AA6063/SiC composites and the effect of pulse on time is very significant in reducing the surface roughness and pulse off time plays an important role in producing minimum cutting width.

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Mouralova, Katerina, Pavel Hrabec, Libor Benes, Jan Otoupalik, Josef Bednar, Tomas Prokes, and Radomil Matousek. "Verification of Fuzzy Inference System for Cutting Speed while WEDM for the Abrasion-Resistant Steel Creusabro by Conventional Statistical Methods." Metals 10, no. 1 (January 6, 2020): 92. http://dx.doi.org/10.3390/met10010092.

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Wire electrical discharge machining is an unconventional machining method for the production of complex-shaped and very precise parts. Because of the high energy consumption of this machining process, it is necessary to maximize the cutting speed for its appropriate implementation. The abrasion-resistant steel Creusabro 4800 was chosen as the test material for this experiment, which is widely used especially for machines working in mines and quarries. In order to maximize the cutting speed, a fuzzy inference system (FIS) has been built, which uses 18 expert propositions to “model” the cutting speed based on five selected input parameters: gap voltage, pulse on time, pulse off time, discharge current, and wire feed. The obtained results were further verified by a design of experiment consisting of 33 tests for five selected input factors. Using the fuzzy inference system, the optimum machine parameters setup was found to maximize the cutting speed, in which the gap voltage = 60 V, pulse on time = 10 µs, pulse off time = 30 µs, wire feed = 10 m∙min−1 and discharge current = 35 A. The predicted value of the cutting speed using the fuzzy inference system is 6.471 mm∙min−1.

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Manoj, I. Vishal, S. Narendranath, and Alokesh Pramanik. "Optimization and Prediction of Machining Responses Using Response Surface Methodology and Adaptive Neural Network by Wire Electric Discharge Machining of Alloy-X." Materials Science Forum 1026 (April 2021): 28–38. http://dx.doi.org/10.4028/www.scientific.net/msf.1026.28.

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Wire electric discharge machining non-contact machining process based on spark erosion technique. It can machine difficult-to-cut materials with excellent precision. In this paper Alloy-X, a nickel-based superalloy was machined at different machining parameters. Input parameters like pulse on time, pulse off time, servo voltage and wire feed were employed for the machining. Response parameters like cutting speed and surface roughness were analyzed from the L25 orthogonal experiments. It was noted that the pulse on time and servo voltage were the most influential parameters. Both cutting speed and surface roughness increased on increase in pulse on time and decrease in servo voltage. Grey relation analysis was performed to get the optimal parametric setting. Response surface method and artificial neural network predictors were used in the prediction of cutting speed and surface roughness. It was found that among the two predictors artificial neural network was accurate than response surface method.

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Tan, Jun Qi, and Mohd Yazid Abu. "Performance evaluation of wire electrical discharge machining on Titanium Alloy." Journal of Modern Manufacturing Systems and Technology 1, no. 1 (September 13, 2018): 27–38. http://dx.doi.org/10.15282/jmmst.v1i1.174.

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The experimental carried out to aim at the selection of the best condition machining parameter combination for wire electrical discharge machining (WEDM) of titanium alloy (Ti–6Al–4V). By using Design Expert 10 software, a series of experiments were performed by selecting pulse-on time, pulse-off time, servo voltage and peak current as parameters. The responses that considered were cutting speed, material removal rate, sparking gap and surface roughness. Based on ANOVA analysis, the effect from the parameters on the responses was determined. The optimum machining parameters setting for the maximum cutting speed, minimum sparking gap and minimum surface roughness were found by proceed optimization experiment. Then, each optimization response had their own combination setting on WEDM to cut titanium alloy. 3D response surface graph such as dome and bowl shape represent maximum and minimum point for the solutions had shown in the report. Finally, predicted and actual value from the experiment have been calculated for validation.

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ABLYAZ, TIMUR RIZOVICH, and KARIM RAVILEVICH MURATOV. "THE TECHNOLOGICAL QUALITY CONTROL OF STACK CUTTING BY WIRE ELECTRICAL DISCHARGE MACHINING." Surface Review and Letters 24, no. 05 (October 19, 2016): 1750060. http://dx.doi.org/10.1142/s0218625x17500603.

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Electrical discharge machining (EDM) of a stack allows achieving high precision and quality of cut surfaces and, therefore, this method is indispensable for state-of-the-art mechanical engineering. The procedure of EDM is carried out with wire-cutting machines. The characterization of constructive parameters of a stack of material and applying of an efficient cutting regime are the most important preconditions providing high precision of EDM. The goal of this work is the improvement of quality and efficiency of wire electrical discharge machining (WEDM) technology by theoretical and experimental studies of the WEDM process. The subsequent development of theoretical and empirical models allowing for the calculation of the quality parameters of treated surfaces is realized. It is shown that the main characteristics of cut surfaces are the roughness, size precision, error profile and structure of a surface layer. For the first time, the regression dependencies between the main parameters of the WEDM process (pulse [Formula: see text]-time [Formula: see text], off-time [Formula: see text], the height of the stack and the physicomechanical properties of the cut materials are obtained. The experimental study of WEDM confirms the results of mathematical modeling. It is proved experimentally that at an interlayer gap higher than 0.1[Formula: see text]mm, the cutting process stability is decreasing whereas the probability of the electrode fracture is increasing. However, it is found that at [Formula: see text]s and [Formula: see text]s, a stable cutting regime leading to bundling of the stock materials made from steel 65Γ can be realized.

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Bayraktar, Şenol, and Yakup Turgut. "Effects of different cutting methods for electrical steel sheets on performance of induction motors." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 7 (August 29, 2016): 1287–94. http://dx.doi.org/10.1177/0954405416666899.

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In this study, by cutting electrical steel stator laminations, one of the most important components of electrical machines by different cutting methods, the effects of these cutting methods on motor efficiency are investigated. As cutting methods, wire electrical discharge machining, punching, laser and abrasive water jet methods are used. Burr formation at the cutting edge leads to short circuits during the steel packaging and causes magnetic losses in steel packages to increase. In addition, depending on the cutting methods, electrical steel lamination insulation layer is damaged as a result of residual and thermal stress formations. These negative conditions cause iron, friction and windage, stator, rotor and additional load losses occurred in the engine to decrease. In order to minimize these cases, electrical steel stator laminations are cut with the cutting parameters determined as a result of pre-cut tests and 5.5-kW induction motors are manufactured. These manufactured motors, according to IEC 60034-2-1-1B method, are subjected to no-load performance tests in addition to six different loading ratios of 25%–50%–75%–100%–115%–125% and constant 50 Hz frequency. As a result of the test measurements, losses occurred in electrical steels cut with abrasive water jet are found to be higher than the other cutting methods. In addition, in terms of the motor performance, the best results are obtained with wire electrical discharge machining cutting method.

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Kang, Jeong Jin, Seok Kwan Hong, Sang Yong Lee, Sang Chul Lee, and Sung Hee Lee. "Effect of Process Conditions on Hydrophobic Characteristics of Injection Molded Silicone Rubber Surface Replicated from Electric Discharge Machined Surface." Applied Mechanics and Materials 465-466 (December 2013): 1272–76. http://dx.doi.org/10.4028/www.scientific.net/amm.465-466.1272.

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In recent years, a lot of effort has gone into many researchers making components of specific functions, mimicking various microstructures in nature. In this study, a super hydrophobic surface on injection-molded liquid silicone rubber was fabricated, mimicking micro-bumps on a lotus leaf. Original patterns were machined by electric discharge machining and liquid silicone rubber was injection-molded by using the original patterns as molds. The hydrophobic characteristics of injection-molded liquid silicone rubber surface replicated from the original electric discharge machined surface were studied. According to variations of injection molding process parameters like mold temperature, injection speed, injection pressure, vacuum, etc. the variations of water contact angles, as a hydrophobic index, measured on the injection-molded surfaces were examined. The liquid silicone rubber surface molded from wire-cutting electric discharge machined surface at mold temperature 120°C, injection speed 5 mm/sec, injection pressure 70 bar and in a vacuum cavity showed water contact angle of 148°, which is close to super-hydrophobic level.

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Sivaraman, B., Senthil Padmavathy, P. Jothiprakash, and T. Keerthivasan. "Multi-Response Optimisation of Cutting Parameters of Wire EDM in Titanium Using Response Surface Methodology." Applied Mechanics and Materials 854 (October 2016): 93–100. http://dx.doi.org/10.4028/www.scientific.net/amm.854.93.

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This Aim of this paper is to analyse the effect of machining parameters of wire electrical discharge machining (WEDM) on workpiece material titanium, that were now widely used in many applications because of its technical benefits. Conventional method of machining the material will make the work piece to crack or flaws due to chipping, presence of burrs and cracking. Wire cut Electrical discharge machining techniques have been already tried with some other high strength materials which is complicated to cut. To prove the feasibility of machining the titanium, many experiments were carried out based on RSM. Hence by the head wire electrical discharge machining process is to be used to machining the work piece material (titanium) and the effect of various control parameters on the response parameters were analysed and optimized and the optimal combination of control parameters were found to get higher metal removal rate and surface finish using Response Surface Methodology.

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Lenin, Singaravelu D., A. Uthirapathi, Ramana Reddy P. S. Venkata, and Muthukannan Durai Selvam. "Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of Ti-6Al-4V Using Zinc Coated Brass Wire." Applied Mechanics and Materials 592-594 (July 2014): 416–20. http://dx.doi.org/10.4028/www.scientific.net/amm.592-594.416.

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The present paper describes the influence of pulse-on-time on performance features such as Metal Removal Rate (MRR), Kerf width, Surface Roughness (SR) on cutting Titanium alloy (Ti-6Al-4V) in wire electrical discharge machining (WEDM) using zinc coated brass wire. The deionised water is used as dielectric fluid. The process parameters such as wire tension, wire speed, flushing pressure, discharge current, sparking voltage and pulse off time have kept constant at appropriate values throughout the experiment and the pulse on time is varied at nine different intervals. It was found that pulse-on-time is the most significant factor which greatly influences MRR, kerf width, and SR. It was also observed that taper at the end of cutting zone which is unavoidable occurrence for the machined part. This is due to the erosion of wire material. The surface roughness increases with increase in pulse on time also with higher rate of MRR.

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Kumar, Anish, Renu Sharma, Arun Kumar Gupta, and Jay Ram Yadav. "Mathematical Modeling and Optimization of Wire Electric Discharge Machining Parameters on Inconel 825 Using Desirability Method." Journal of Computational and Theoretical Nanoscience 17, no. 6 (June 1, 2020): 2441–50. http://dx.doi.org/10.1166/jctn.2020.8914.

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The present research work mainly emphases on experimentation, analysis and optimization of machining parameters during WEDM on Inconel 825. Based on Box-Behenken Design, 29 experimental runs were executed on WEDM using 0.25 mm dia half hard brass wire and de-ionized water as dielectric. Controllable parameters pulse on time (Ton), pulse off time (Toff), spark gap voltage (SV) and wire feed (WF) are varied up to three levels to study their influence on response measures cutting speed (CS) and gap current (Ig). Experimental models were developed by employing RSM. Design expert software 7.0.0 was considered for design of experiments and developing the mathematical model. Graphical model analysis has been done with the help of Analysis of Variance (ANOVA). Ton Toff and SV have major influencing factors on responses where, as wire Feed was insignificant. To achieve optimal parameter combination, multi-objective optimization of responses is performed using desirability method. Confirmation test is performed at optimal combination of parameters provided by desirability function to validate the study. Hence, predicted value lies in correspondence with the experimental findings.

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Kumar, Anshuman, Chandramani Upadhyay, and Vivekananda Kukkala. "Study of Surface Characterization and Parametric Optimization during Wire Electric Discharge Machining for Inconel 625." Materials Science Forum 978 (February 2020): 97–105. http://dx.doi.org/10.4028/www.scientific.net/msf.978.97.

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This presented article focuses on surface characterization and assessing the satisfactory machining condition of WEDMed Inconel 625. This work material has been received remarkable attention to the industrial and academic organization for its end use applications. WEDM is well-known machining process for intricate shape cutting and machining hard materials. The experimental design was planned according to L27 orthogonal array (OA), by varying controllable process parameter (i.e. Wire-Tension, Wire-speed, Flushing-Pressure, Discharge-Current and Spark-on Time), each parameter varied at four discrete levels, within the selected parametric domain. WEDMed surfaces have been investigated with a focus to the surface characterization of selected machined surface through captured images from scanning electron microscope (SEM). Eventually, multi-response optimization of process parameters was sought by using a combination of nonlinear regression modelling, fuzzy inference system (FIS) with Teaching Learning-Based Optimization (TLBO) algorithm. The obtained TLBO result was compared with the Genetic algorithm (GA). The results show that optimization algorithms are effective tools for getting satisfactory optimal machining conditions during WEDM process of Inconel 625.

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Kapoor, Jatinder, Jaimal Singh Khamba, and Sehijpal Singh. "Effect of Different Wire Electrodes on the Performance of WEDM." Materials Science Forum 751 (March 2013): 27–34. http://dx.doi.org/10.4028/www.scientific.net/msf.751.27.

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In this paper, the effect of different wire electrodes used in wire electrical discharge machining (WEDM) on the machining characteristics of AISI D3 die steel has been presented. Three process parameters, namely type of wire (brass wire, zinc coated wire and composite wire), pulse on time and peak current have been considered. The process performance is measured in terms of cutting speed and surface roughness. The research outcome will identify the important parameters and their effect on performance characteristics while machining AISI D3 material with different wire electrodes. The analysis of variance (ANOVA) of multilevel factorial design indicated that all the selected parameters have significant effect on the performance characteristics. The study indicated the improvement in surface roughness with brass wire over other wires. Maximum cutting speed was obtained with composite wire as compared to zinc coated and brass wire. Additionally, scanning electron microscope (SEM) examination highlighted important features of machined work piece surface.

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Zhang, Shi Jin, Yu Qiang Wu, and Yan Li Wang. "Wire Electrical Discharge Machining – High Speed VS Abrasive Waterjet - A Case Study." Advanced Materials Research 189-193 (February 2011): 4245–55. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.4245.

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Technological advancement, on the one hand, made Electrical Discharge Machining (EDM) much faster. One example of that is the presence of Wire Electrical Discharge Machining – High Speed (WEDM-HS) machine, which makes the material removal rate as high as 80 . On the other hand, it also made Abrasive Waterjet (AWJ) achieve much better quality surface and tighter tolerance. As a result, these two types of machining process have converged to the point where they can complement one another quite nicely in selected applications. However, it does not mean user may pick any one for their applications. The proper selection not only decreases the manufacturing costs but also achieves better quality. This paper focuses on comparing WEDM-HS with AWJ by actually cutting a special designed sample. Through comparison from several aspects which include dimension precision, surface roughness, cost, cutting time and surface damage, a proper selection guidance for regular user has been provided.

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Ma, Jun, Wuyi Ming, Jinguang Du, Hao Huang, Wenbin He, Yang Cao, and Xiaoke Li. "Integrated optimization model in wire electric discharge machining using Gaussian process regression and wolf pack algorithm approach while machining SiCp/Al composite." Advances in Mechanical Engineering 10, no. 9 (September 2018): 168781401878740. http://dx.doi.org/10.1177/1687814018787407.

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To further improve prediction accuracy and optimization quality of wire electrical discharge machining of SiCp/Al composite, trim cuts were performed using Taguchi experiment method to investigate the influence of cutting parameters, such as pulse duration ( Ton), pulse interval ( Toff), water pressure ( Wp), and wire tension ( Wt)), on material removal rate and three-dimensional surface characteristics ( Sq and Sa). An optimization model to predict material removal rate and surface quality was developed using a novel hybrid Gaussian process regression and wolf pack algorithm approach based on experiment results. Compared with linear regression model and back propagation neural network, the availability of Gaussian process regression is confirmed by experimental data. Results show that the worst average predictive error of five independent tests for material removal rate, Sq, and Sa are not more than 10.66%, 19.85%, and 22.4%, respectively. The proposed method in this article is an effective method to optimize the process parameters for guiding the actual wire electrical discharge machining process.

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Chakraborty, Sadananda, and Dipankar Bose. "Improvement of Die Corner Inaccuracy of Inconel 718 Alloy Using Entropy Based GRA in WEDM Process." Advanced Engineering Forum 20 (January 2017): 29–41. http://dx.doi.org/10.4028/www.scientific.net/aef.20.29.

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Abstract:

Wire Electric Discharge Machining is one of the non-traditional machining process to develop and generate many complicated shapes with very much accuracy. Improper selection of cutting parameters may result in erroneous configuration and shapes. When cutting curve profile in WEDM process, it has been found out that the magnitude of corner inaccuracy in terms of uncut area at the corner of the die is much higher than the corner inaccuracy at the corner of the punch due to the excess material removal. In this study entropy based grey relation analysis has been used to identify the optimal cutting parameter for WEDM process. ANOVA has been adopted to distinguish the most consequential factors. Inconel 718 has been used as a work-piece material which is a new advance material and it has wide range of industrial application. The characteristics of the machined surfaces of Inconel 718 alloy have also been analyzed through scanning electron microscope (SEM).

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Journal articles on the topic 'Electric discharge wire cutting'

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