Journal articles: 'WIRE-CUT EDM PROCESS'

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Sen, Ruma, P. Charkraborti, and J. Debbarma. "Wear Behavior in Wire of Wire Cut EDM." Applied Mechanics and Materials 704 (December 2014): 70–76. http://dx.doi.org/10.4028/www.scientific.net/amm.704.70.

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Wire electrical discharge machining (WEDM) is a specialized thermal machining process, capable of accurately machining parts with different hardness, complex shapes and sharp edges that are very difficult to be machined by the traditional machining processes. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted noncontact technique of material removal.In this paper, the effects of various process parameters of WEDM like pulse on time (Ton), peak current (IP), wire feed (WF) and wire tension (WT) have been investigated to study their impact on wear of wire of ELECTRONICA SPRINTCUT WEDM machine.It is found that the wear is influenced with increase in pulse on time (Ton) and wire tension.

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Beltrami, Ivano, Axel Bertholds, and Dirk Dauw. "A simplified post process for wire cut EDM." Journal of Materials Processing Technology 58, no. 4 (April 1996): 385–89. http://dx.doi.org/10.1016/0924-0136(95)02212-0.

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Muttamara, Apiwat, and Patittar Nakwong. "Enhancing Wire-EDM Performance with Zinc-Coated Brass Wire Electrode and Ultrasonic Vibration." Micromachines 14, no. 4 (April 16, 2023): 862. http://dx.doi.org/10.3390/mi14040862.

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This study aimed to investigate the performance of zinc-coated brass wire in wire-cut electrical discharge machining (EDM) using an ultrasonic-assisted wire on tungsten carbide. The research focused on the effect of the wire electrode material on the material removal rate, surface roughness, and discharge waveform. Experimental results demonstrated that using ultrasonic vibration improved the material removal rate and reduced surface roughness compared to conventional wire-EDM. Cross-sectional SEM of the white layer and discharge waveform were investigated to explain the phenomena of ultrasonic vibration in the wire-cut EDM process.

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Satynarayana, Kosaraju, Kumkuma Rajkiran, Pujari Anil kumar, and D. Chakradhar. "A Role of cryogenic in Wire cut EDM process." E3S Web of Conferences 184 (2020): 01067. http://dx.doi.org/10.1051/e3sconf/202018401067.

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Novel techniques are being focused on the enrichment of the performance characteristics under different machining processes. Cryogenic is one of such novel practices that tunes the surface integrity with vast variations with the traditional machining processes. Dimensional accuracy, surface roughness, material removal rate with less reduction in scrap of material is one of the prior targets of production process. Wire cut Electro Discharge Machining (WEDM) is one method that satisfy with upgrading performance characteristics. In order to step-up these performance characteristics in attaining superior quality, cryogenics practices have collaborated with the WEDM process. Present paper deals with the reviews of the researchers that have been performed over cryogenic treated WEDM process. Effect of performance characteristics like pulse on, pulse off, current, voltage, wire tension, wire feed is discussed with relation to material removal rate, tool wear rate and surface roughness evolved. Key concept of paper is to include the research ideology with best feasible techniques that can prevail in production practice in order of contribute to the forthcoming researches in industrial and production departments.

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Bergs, T., L. Welschof, T. Herrig, and A. Klink. "Energetic Characterization of Trim Cut Process Signals in Wire EDM." Procedia CIRP 95 (2020): 262–67. http://dx.doi.org/10.1016/j.procir.2020.02.281.

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Lok, Y. K., and T. C. Lee. "Processing of advanced ceramics using the wire-cut EDM process." Journal of Materials Processing Technology 63, no. 1-3 (January 1997): 839–43. http://dx.doi.org/10.1016/s0924-0136(96)02735-5.

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A. Kumar, N. Dutt, V. Pratap Singh, C. S. Meena, and A. Prasad. "Performance Evaluation of WEDM using Parametric Variation." Journal of Mechanical Engineering: Prakash 01, no. 01 (2022): 07–13. http://dx.doi.org/10.56697/jmep.2022.1102.

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Wire cut Electrical-Discharge Machining (Wire-EDM) is a variation of EDM process which utilizes a thin wire (around 0.18mm) for material removal. In this article surface roughness in WEDM process was analysed using Taguchi method and experimental results. In experiments it was observed that by increasing the current surface roughness increases and rough surface is produced. Peak current is the most critical parameter having a contribution of 82.12%.

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Kumarswamy, Y., P. Durga Ganesh, K. Ravi Kumar, S. Sai Varun, G. Jagan Vamsi, and Y. Phaneendra. "Optimize the process parameters of wire EDM and to analyse the welding characteristics of tig welding joints using AISI 308." E3S Web of Conferences 391 (2023): 01043. http://dx.doi.org/10.1051/e3sconf/202339101043.

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Wire Cut EDM technique is widely used to make small and precision cuts. Generally, a material with fragile geometry and hard structure is cut using a wire cut EDM. The main advantage of this method is that, it is a non-conventional machining process therefore it does not have a contact between the tool (wire) and the workpiece. This advantage gives it an edge over other machining techniques and it makes the process capable of machining even the weak structured and delicate materials. In the present experimental work, by using various machining parameters (Pulse on Time, Pulse off Time, and Wire Speed) were optimized using Taguchi’s L9 orthogonal array. Welding is most the important industrial processes, therefore lots of techniques have been developed to get an efficient and low-cost welding process for different types of materials. In this we will discuss about the welding characteristics of the of tig welding joints produced using different currents. That is, by changing the voltages for the number of passes to improve and strengthen the welded joint The research work aims to optimize the wire cut EDM process parameters for AISI 308 steel and analyze the welding characteristics of Tungsten Inert Gas (TIG) welded joints of the same material. The study intends to find the optimum combination of process parameters that would lead to the highest material removal rate, lowest wear rate, and best tensile properties of the material.

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Mohamedosman Elyass, Waddah, Vishal Sharma, Ganesh Kantak, and Mohd Mukhtar Alam. "Performance Investigation of Wire EDM Process Parameters." IOP Conference Series: Materials Science and Engineering 1224, no. 1 (January 1, 2022): 012001. http://dx.doi.org/10.1088/1757-899x/1224/1/012001.

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Abstract It is exceptionally difficult to create confusing geometry in such a material using traditional machining measurement. At present, companies use a non-regular machining strategy which uses energies like electricity, chemical, sound, light, etc. which are useful for machining hard materials. WEDM machines are used to cut complex and simple patterns and have the potential to achieve the maximum production capacity since the last few decades. This study was carried out in two parts. The first segment was consolidated with analyses of the Taguchi method depending on the signal-to-noise ratio (S / N) and regression modelling for the S / N ratio. In the second segment, the model condition was created using the RSM methodology. L16 orthogonal array was used with four levels of parameters namely, pulse on time, pulse off time, wire feed rate and peak current to find the effects on optimal response variables namely, cutting time, cutting rate, overcut and dimensional deviations. The results of the regression analysis showed that there was significant effect of pulse on/off and peak current on the cutting time and for cutting rate there was also significant effect of wire feed rated. Therefore, it can be concluded that all the four process parameters can affect the response variables.

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Nandakumar, C., B. Mohan, and S. Srisathirapathy. "Optimization of Process Parameters of Titanium Alloy Grade 5 Using CNC Wire-Cut EDM." Advanced Materials Research 984-985 (July 2014): 56–61. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.56.

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Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact strength are increasing. As these materials pose severe difficulty to be machined by conventional methods, Wire-cut Electric Discharge Machining (Wire EDM) machines are employed to machine them. The ultimate requirement of any machining process being fine surface finish, is accurately satisfied by wire-cut EDM process. Hence this project aims at obtaining the best surface finish by optimizing various process parameters affecting the machining conditions. With the assistance of Taguchi quality engineering, various number of experiments will be conducted by varying the process parameters at various levels. The output response variable being surface roughness, will be measured for all the number of experiments conducted. As the lowest value of surface roughness indicates the best surface finish, the optimum parameter level combination would be analyzed which gives desired surface finish. These optimized values of various parameters would then be used in performing machining operation in order to obtain desirable outputs.

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VS Ram Prasad, A., Koona Ramji, and B. Raghu Kumar. "Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method." International Journal of Engineering & Technology 7, no. 2.8 (March 19, 2018): 10. http://dx.doi.org/10.14419/ijet.v7i2.8.10316.

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Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

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Goswami, Amitesh, and Jatinder Kumar. "Surface Topography and Kerf Study of Nimonic 80A Using Wire-Cut EDM." Materials Science Forum 808 (December 2014): 35–41. http://dx.doi.org/10.4028/www.scientific.net/msf.808.35.

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Nimonic-80A is a nickel based super alloy which is specifically used in aerospace industry for its high strength to weight ratio and corrosion resistance. This paper presents the influence of process parameters of wire cut Electrical Discharge Machining (WEDM) during the machining of Nimonic 80A with brass wire as electrode and optimization of machining parameters on kerf width. Process parameters (pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed and wire tension) have been investigated using L27orthogonal array. With the assistance of Taguchi quality design, ANOVA and F-test, significant parameters affecting the kerf have been identified. The surface topography of machined samples has been studied in correlation with the rate of input energy into the spark.

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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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Natarajan, K., H. Ramakrishnan, Amel Gacem, V. Vijayan, K. Karthiga, H. Elhosiny Ali, B. Prakash, and Addisalem Mekonnen. "Study on Optimization of WEDM Process Parameters on Stainless Steel." Journal of Nanomaterials 2022 (July 12, 2022): 1–7. http://dx.doi.org/10.1155/2022/6765721.

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Stainless steel is a material which has high corrosive resistance and oxidation resistance at high temperature with the combination of chromium, nickel, and niobium as a primary constituent. This material which is difficult to machine with complex shape is taken by using wire cut electric discharge machining. Wire electrical discharge machining is a nontraditional process widely taken for cutting and machining for complex shapes. This review paper involves wire cut EDM optimization parameters. Pulse interval, pulse duration, wire feed, voltage, and mean current are the operational parameters. The Taguchi orthogonal array method, analysis of variance (ANOVA), and grey relation analysis (GRA) methods are taken for different kinds of machining various kinds of materials, and different kinds of result with best material removal rate (MRR) and surface roughness (SR) are analyzed. This work suggests the most influencing process parameters and best optimization method for various steel materials.

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Kawata, Akiyoshi, Akira Okada, Yasuhiro Okamoto, and Haruya Kurihara. "Influence of Nozzle Jet Flushing on Wire Breakage in 1st-Cut Wire EDM from Start Hole." Key Engineering Materials 749 (August 2017): 130–35. http://dx.doi.org/10.4028/www.scientific.net/kem.749.130.

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In wire EDM process, it is important to smoothly exclude debris and bubbles generated in the working gap for keeping stable performance. Much debris stagnation in the gap would cause frequent occurrence of discharge concentration and secondary discharge, which results in unstable machining performance, such as frequent wire breakage, low removal rate, and low shape accuracy. Therefore, a jet flushing of working fluid using upper and lower jet nozzles has been conventionally applied for excluding the debris and bubbles from the machined kerf. Nevertheless, it is well known that the wire often breaks when the machined kerf length is a few mm from the start hole in 1st-cut wire EDM. The influence of machined kerf length on the flow field, the debris exclusion, and the wire behavier caused with hydrodyanamic force by the jet flushing should be made clear.In this study, variations of flow field in the kerf, the debris accumulation state and the wire deflection caused jet flushing with machined length were analytically investigated by CFD (computational fluid dynamics) and structural analysis when 1st-cut wire EDM was done from a small start hole. Moreover, the effects of machined kerf length on the wire deflection and wire breakage were discussed. Wire breakage frequency experiments showed that wire tended to frequently break at a certain machined kerf length, where the wire deflection rapidly increased and the debris particle residence time in the gap became long.

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MAITY, K. P., and M. CHOUBEY. "A REVIEW ON VIBRATION-ASSISTED EDM, MICRO-EDM AND WEDM." Surface Review and Letters 26, no. 05 (June 2019): 1830008. http://dx.doi.org/10.1142/s0218625x18300083.

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Electrical discharge machining (EDM) is an unconventional machining process used for machining of hard-to-cut materials. Both EDM and micro-EDM processes are extensively used for producing dies and molds, complex cavities, and 3D structures. In recent years, researchers have intensively focused on improving the performance of both micro-EDM and EDM processes. This paper reviews the research work carried out by the researchers on vibration-assisted EDM, micro-EDM, and wire EDM. The consolidated review of this research work enables better understanding of the vibration-assisted EDM process. This study also discusses the influence of vibration parameters such as vibration frequency and amplitude on the material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR). The important issues and research gaps in the respective area of research are also presented in this paper.

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Abbasi, Junaid Ali, Mirza Jahanzaib, Muhammad Azam, Salman Hussain, Ahmad Wasim, and Musharaf Abbas. "Effects of wire-Cut EDM process parameters on surface roughness of HSLA steel." International Journal of Advanced Manufacturing Technology 91, no. 5-8 (December 24, 2016): 1867–78. http://dx.doi.org/10.1007/s00170-016-9881-9.

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Kumar, Amit, Tarun Soota, and Jitendra Kumar. "Optimisation of wire-cut EDM process parameter by Grey-based response surface methodology." Journal of Industrial Engineering International 14, no. 4 (March 21, 2018): 821–29. http://dx.doi.org/10.1007/s40092-018-0264-8.

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Jakhar, Balram, Puneet Katyal, and Vishal Gulati. "Investigating the Process Parameters for optimization on Inconel 600 using wire cut EDM." International Journal of Advance Research and Innovation 3, no. 3 (2015): 90–97. http://dx.doi.org/10.51976/ijari.331512.

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This study presents the investigation on surface roughness and cutting speed using wire electric discharge machine for nickel based alloy (Inconel 600).Taguchi’s design of experiments methodology has been used for scheduling and designing the experimental array.Taguchi’s L-18 orthogonal array was selected and where in taper angle, peak current, pulse-on time, pulse-off time and dielectric flow rate has been considered as variable input parameters during machining. The result of the study reveals that among machining parameters it is preferably to go for increasing the value of peak current and pulse on time for better cutting speed but it is constrained when better surface finish is required. Larger value of taper angle increases cutting speed up to limited extent. The predicted optimal values for CS and SR are found to be 3.08 mm/min, 1.37 μm for single response optimization respectively. The confirmation experiments are also conducted and the values for CS and SR are found to be 3.06 mm/min and 1.29 μm for single response optimization respectively.

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Satyanarayana, K., B. Ramya Krishna, M. Bhargavi, R. Eswari Vasuki, and K. Raj Kiran. "Taguchi Optimization In Machining Inconel 600 With WEDM Process Using Cryogenically Treated Brass Wire." E3S Web of Conferences 309 (2021): 01110. http://dx.doi.org/10.1051/e3sconf/202130901110.

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Wire electric discharge machining (WEDM) is one amongst the unconventional machining processes which might cut all kinds of shapes with an accuracy of +/−0.001mm. It will cut the materials that conduct electricity and can even cut the exotic metals like tungsten carbide, Hastelloy, Inconel etc. In the present work, machining on Inconel 600 by wire EDM with cryogenically treated brass wire is performed. Brass wire of 0.25mm diameter has been cryogenically treated at −90°C, −100°C and −110°C temperatures separately. An Experimental layout is designed as per Taguchi’s L-9 orthogonal array and experiments were conducted by varying machining parameters viz. Voltage, Pulse ON time and Pulse OFF time. The machining parameters are optimized using Taguchi’s methodology for minimum surface roughness and maximum metal removal rate (MRR). A Mathematical regression model for surface roughness and MRR is generated with the help of regression analysis. Through the Analysis of Variance (ANOVA) It was found that for MRR, pulse on time is the foremost contributing factor with 32.69% and for surface roughness, pulse off time is the foremost contributing factor with 23.59%.

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Wu, Yung-Yi, Tzu-Wei Huang, and Dong-Yea Sheu. "Desktop Micro-EDM System for High-Aspect Ratio Micro-Hole Drilling in Tungsten Cemented Carbide by Cut-Side Micro-Tool." Micromachines 11, no. 7 (July 11, 2020): 675. http://dx.doi.org/10.3390/mi11070675.

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Tungsten cemented carbide (WC-Co) is a widely applied material in micro-hole drilling, such as in suction nozzles, injection nozzles, and wire drawing dies, owing to its high wear resistance and hardness. Since the development of wire-electro-discharge grinding (WEDG) technology, the micro-electrical discharge machining (micro-EDM) has been excellent in the process of fabricating micro-holes in WC-Co material. Even though high-quality micro-holes can be drilled by micro-EDM, it is still limited in large-scale production, due to the electrode tool wear caused during the process. In addition, the high cost of precision micro-EDM is also a limitation for WC-Co micro-hole drilling. This study aimed to develop a low-cost desktop micro-EDM system for fabricating micro-holes in tungsten cemented carbide materials. Taking advantage of commercial micro tools in a desktop micro-EDM system, it is possible to reach half the amount of large-scale production of micro-holes. Meanwhile, it is difficult to drill the deep and high aspect ratio micro-holes using conventional micro-EDM, therefore, a cut-side micro-tool shaped for micro-EDM system drilling was exploited in this study. The results show that micro-holes with a diameter of 0.07 mm and thickness of 1.0 mm could be drilled completely by cut-side micro-tools. The roundness of the holes were approximately 0.001 mm and the aspect ratio was close to 15.

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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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Liu, J. F., and Y. B. Guo. "Process Capability of Wire-EDM of NiTi Shape Memory Alloy at Main Cut and Trim Cut Modes." Procedia Manufacturing 1 (2015): 904–14. http://dx.doi.org/10.1016/j.promfg.2015.09.083.

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Zhao, Jian Chuang, Jian Dong Hu, Fan You Meng, and Yao Min Wang. "Machinability and Material Removal Mechanism of Face Centred Cubic (FCC) Conductive Ceramic TiBCN in EDM Processing." Key Engineering Materials 680 (February 2016): 147–51. http://dx.doi.org/10.4028/www.scientific.net/kem.680.147.

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Fcc-TiBCN powder synthesized by boronizing of Ti was pressured into monolithic block by hot pressing (HP) method. Then the block material was machined by wire-cut EDM. The machinability and the material removal mechanisms were discussed of Fcc-TiBCN block in wire-cut EDM. Results show that the machinability of Fcc-TiBCN is satisfying. The discharge current has little relationship on surface roughness in the range of factory-adjusted optimum settings. The discharge duration and pulse interval time play an important role on the quality of machined surface and EDM machining efficiency. In order to obtain excellent quality of the machined surface, the number of power tube turned on can not exceed 6, and the pulse interval time must be as long as possible. The mini roughness of machined surface is 0.4μm～0.6μm as the number of power tube turned on is 5, the pulse interval time and discharge duration is set in the range of 20～22μs and 65～75μm, respectively. There are three material removal mechanisms of TiBCN conductive ceramic in the EDM machining process: spalling, melting and evaporation. Spalling is the main mechanism resulted by thermal stress superposing.

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Sathish, Thanikodi, Vinayagam Mohanavel, Khalid Ansari, Rathinasamy Saravanan, Alagar Karthick, Asif Afzal, Sagr Alamri, and C. Ahamed Saleel. "Synthesis and Characterization of Mechanical Properties and Wire Cut EDM Process Parameters Analysis in AZ61 Magnesium Alloy + B4C + SiC." Materials 14, no. 13 (July 1, 2021): 3689. http://dx.doi.org/10.3390/ma14133689.

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Wire Cut Electric Discharge Machining (WCEDM) is a novel method for machining different materials with application of electrical energy by the movement of wire electrode. For this work, an AZ61 magnesium alloy with reinforcement of boron carbide and silicon carbide in different percentage levels was used and a plate was formed through stir casting technique. The process parameters of the stir casting process are namely reinforcement %, stirring speed, time of stirring, and process temperature. The specimens were removed from the casted AZ61 magnesium alloy composites through the Wire Cut Electric Discharge Machining (WCEDM) process, the material removal rate and surface roughness vales were carried out creatively. L 16 orthogonal array (OA) was used for this work to find the material removal rate (MRR) and surface roughness. The process parameters of WCEDM are pulse on time (105, 110, 115 and 120 µs), pulse off time (40, 50, 60 and 70 µs), wire feed rate (2, 4, 6 and 8 m/min), and current (3, 6, 9 and 12 Amps). Further, this study aimed to estimate the maximum ultimate tensile strength and micro hardness of the reinforced composites using the Taguchi route.

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Subrahmanyam, M., and T. Nancharaiah. "Optimization of process parameters in wire-cut EDM of Inconel 625 using Taguchi’s approach." Materials Today: Proceedings 23 (2020): 642–46. http://dx.doi.org/10.1016/j.matpr.2019.05.449.

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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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Ashok, R., L. Poovazhagan, S. Srinath Ramkumar, and S. Vignesh Kumar. "Optimization of Material Removal Rate in Wire-EDM Using Fuzzy Logic and Artifical Neural Network." Applied Mechanics and Materials 867 (July 2017): 73–80. http://dx.doi.org/10.4028/www.scientific.net/amm.867.73.

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Present work aims to develop a model and optimize the material removal rate (MRR) in complex wire electric discharge machining (EDM) process. Initially various percentages of aluminium alloy hybrid Nanocomposites were fabricated by novel ultrasonication method. The sample specimens were cut and machined using wire EDM. Experiments were carried out using Taguchi’s L18 orthogonal array under different cutting parameters like Pulse-on, Pulse- off, current and servo voltage. Fuzzy-based Taguchi method and artificial neural network (ANN) with back propagation algorithm were used to optimize the material removal rate. Both ANN and fuzzy logic based models were developed in MATLAB software and the models were trained for estimating the MRR and improving the machining parameter.

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CHAITANYA REDDY, M., and K. VENKATA RAO VENKATA RAO. "An overview of major research areas in Wire cut EDM on different materials." INCAS BULLETIN 12, no. 4 (December 4, 2020): 33–48. http://dx.doi.org/10.13111/2066-8201.2020.12.4.4.

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WEDM (Wire electrical discharge machining) is a precision machining method for cutting electrically conductive materials. It is an unconventional machining process that produces precision parts that match the dimensional tolerances of our designs within the range of ±0.0001mm. As the residual stress results in premature failure of parts, the WEDM is preferred for hard to machine materials such as Inconel, Nickel, and other Super alloys. In the present paper, earlier and recent work was reviewed, segregated and evaluated on the effect of wire material, diameter, dielectric fluid, wire wear, pulse on and off times and machining characteristics such as kerf size, machining efficiency, material surface characteristics, etc. This paper also focused on hybrid and ultrasonic-assisted WEDM used for machining of different materials. This paper discussed the major research studies in WEDM.

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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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Ablyaz, Timur Rizovich, Evgeny Sergeevich Shlykov, Karim Ravilevich Muratov, and Sarabjeet Singh Sidhu. "Analysis of Wire-Cut Electro Discharge Machining of Polymer Composite Materials." Micromachines 12, no. 5 (May 18, 2021): 571. http://dx.doi.org/10.3390/mi12050571.

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This study presents the analysis of wire-cut electro-discharge machining (WIRE-EDM) of polymer composite material (PCM). The conductivity of the workpiece is improved by using 1 mm thick titanium plates (layers) sandwiched on the PCM. Input process parameters selected are variable voltage (50–100 V), pulse duration (5–15 μs), and pause time (10–50 μs), while the cut-width (kerf) is recognized as an output parameter. Experimentation was carried out by following the central composition design (CCD) design matrix. Analysis of variance was applied to investigate the effect of process parameters on the cut-width of the PCM parts and develop the theoretical model. The results demonstrated that voltage and pulse duration significantly affect the cut-width accuracy of PCM. Furthermore, the theoretical model of machining is developed and illustrates the efficacy within the acceptable range. Finally, it is concluded that the model is an excellent way to successfully estimate the correction factors to machine complex-shaped PCM parts.

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Sabyrov, Nurbol, M. Jahan, Azat Bilal, and Asma Perveen. "Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)—An Overview." Materials 12, no. 3 (February 10, 2019): 522. http://dx.doi.org/10.3390/ma12030522.

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Many of the industrial processes, including material removal operation for shape generation on the surface of material, exploit the assistance of ultrasonic vibrations. This trend of using ultrasonic vibration in order to improve the process performance is becoming more and more prominent recently. One of the significant applications of this ultrasonic vibration is in the industrial processes such as Electro-discharge machining (EDM), where ultrasonic vibration (UV) is inserted as a medium for enhancing the process performance. Mostly ultrasonic vibration is applied along with the EDM process to increase the efficiency of the process through debris cleansing from the sparking gap. There have been significant changes in ultrasonic assisted technology during the past years. Due to its inherent advantages, ultrasonic assistance infiltrated in different areas of EDM, such as wire cut EDM, micro EDM and die sinking EDM. This article presents an overview of ultrasonic vibration applications in electric discharge machining. This review provides information about modes of UV application, impacts on parameters of performance, optimization and process designing on difficult-to-cut materials. On the bases of available research works on ultrasonic vibration assisted EDM, current challenges and future research direction to improve the process capabilities are identified. Literature suggested improved material removal rate (MRR), increased surface roughness (SR) and tool wear ratio (TWR) due to the application of ultrasonic vibration assisted EDM. However, tool wear and surface roughness can be lessened with the addition of carbon nanofiber along with ultrasonic vibration. Moreover, the application of ultrasonic vibration to both tool and workpiece results in higher MRR compared to its application to single electrode.

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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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Sharma, Hitesh, and Gaurav Mitta. "Experimental study of micro channels for material removal rate by using wire-cut edm process." International Journal of Current Advanced Research 6, no. 3 (March 28, 2017): 2844–49. http://dx.doi.org/10.24327/ijcar.2017.2849.0123.

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Kapoor, Shrey. "Optimisation of Process Parameter for Material Removal Rate of Wire Cut EDM using Taguchi Method." International Journal for Research in Applied Science and Engineering Technology 7, no. 8 (August 31, 2019): 987–91. http://dx.doi.org/10.22214/ijraset.2019.8147.

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Chinnadurai, T., and S. Arungalai Vendan. "Contemplating the Performance Measures of Wire Cut EDM Based on Process Parameters for AISI 4140." Materials Today: Proceedings 2, no. 4-5 (2015): 1067–73. http://dx.doi.org/10.1016/j.matpr.2015.07.009.

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Divya, Marelli, N. Sateesh, and Ram Subbiah. "Review on multi objective optimization of wire cut EDM process parameters using grey relational analysis." Materials Today: Proceedings 26 (2020): 3124–30. http://dx.doi.org/10.1016/j.matpr.2020.02.645.

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Kumar, U. Ashok, G. Saidulu, and P. Laxminaryana. "Experimental investigation of process parameters for machining of Nimonic alloy 75 using wire-cut EDM." Materials Today: Proceedings 27 (2020): 1362–68. http://dx.doi.org/10.1016/j.matpr.2020.02.713.

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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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Doreswamy, Deepak, Anupkumar M. Bongale, Marcin Piekarski, Arunkumar Bongale, Satish Kumar, Danil Yurievich Pimenov, Khaled Giasin, and Krzysztof Nadolny. "Optimization and Modeling of Material Removal Rate in Wire-EDM of Silicon Particle Reinforced Al6061 Composite." Materials 14, no. 21 (October 26, 2021): 6420. http://dx.doi.org/10.3390/ma14216420.

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The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiCp). Machinability of such alloys by traditional methods is challenging due to higher tool wear and surface roughness. The objective of research is to investigate the machinability of SiCp reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (Ton), wire-speed (Ws), voltage (Iv) and pulse-off time (Toff) on material removal rate (MRR) is investigated and their settings are optimized for achieving the high MRR. The experiments are designed by using Taguchi L16 orthogonal arrays. The MRR obtained at different experiments are analyzed using statistical tools. It is observed that all the chosen process parameters showed significant influence of on the MRR with contribution of 27.39%, 22.08%, 21.32%, 15.76% and 12.94% by I, Iv, Toff, Ton and Ws, respectively. At optimum settings, the Wire-EDM resulted in MRR of 65.21 mg/min and 62.41 mg/min for samples with 4% and 8% SiCp. The results also indicated reinforcing SiCp upto 8% showed marginally low influence on MRR. Microstructural investigation of the cut surface revealed the presence of craters with wave pattern on its surface. The top surface of the crater is featured by the recast layers connecting adjacent craters. Further, the statistical model is developed using linear regression to predict the MRR (?2—73.65%) and its predicting accuracy is verified by the confirmation trials. The statistical model is useful for predicting the MRR for different settings of the process parameters. The optimized settings can be used to improve the machining productivity by increasing the MRR while machining of Al6061-SiCp (upto 8 wt. %) alloy by wire-EDM industries.

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Chen, Shun Tong, and Ming Chie Yeh. "Development and Application of a Micro-Honing-Tool." Advanced Materials Research 76-78 (June 2009): 189–94. http://dx.doi.org/10.4028/www.scientific.net/amr.76-78.189.

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The major aim of this study is to present a novel technique for honing the micro-hole. It is difficult that regarding the finish machining of the micro-hole that the diameter is less than 300 m. First, a new process that to on-line accurately fabricate the micro-honing-tool using micro-EDM, micro-co-deposition and micro-wire-EDM is proposed for honing the micro-hole. A micro rod for as the substrate of the micro-tool is formed by wire-EDM and then co-deposited with 0-2 m CBN-abrasives. Subsequently, it is axially and crisscross cut for an appropriate length by micro-wire-EDM to make the crotched microstructure. The whole processes are able to be on-line realized since all working positions are recorded in detail and fabrication technologies are offered sufficiently on the same system. As a result, per the same fabrication-system, the micro-honing process is also on-line conducted. The finished micro-honing-tool is employed directly without unloaded and reloaded. The grinding-block can compactly stick on the wall surface of the micro-hole due to the radial elasticity of the micro-tool and then fast grind away the uneven surface by removal of micro amount. Experimental results demonstrated that the circularity and surface roughness on the hole-wall is evidently improved. Comparing with the obtained machining surface by micro-EDM hole-drilling, the original surface roughness of near one-sixth time can be achieved. It is indicated that the micro-hole can be honed accurately using the proposed technique.

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Gupta, Kapil. "Investigation on Fabrication of SS316 Gear by Wire-EDM." MATEC Web of Conferences 346 (2021): 01044. http://dx.doi.org/10.1051/matecconf/202134601044.

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Manufacturing of miniature gears with good accuracy and quality, and at low cost is a challenging task for traditional manufacturing processes. Wire-cut electric discharge machining (WEDM) has the capacity to machine any conductive material to fabricate typical shaped products like gears with high level of accuracy and quality. In present research, stainless steel (SS) alloy 316 is used to fabricate miniature gears by WEDM. The experimental array is designed according to Response Surface Methodology (RSM) based central composite face centered (CCFC). Four input parameters namely servo feed (SF), duty factor (DF), servo voltage (SV) and wire feed (WF) with three levels each are used for experimental array to investigate the process performance in terms of cutting rate (CR), and product i.e. gear quality in terms of mean roughness depth (Rz) and dimensional deviation (DD). After WEDM parameter optimization, confirmation experiments are performed at the parametric setting by considering equal importance to all response variables. A very close agreement between the experimental and predicted values have been observed.

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Seshaiah, Sathishkumar, Deepak Sampathkumar, Mathanbabu Mariappan, Ashokkumar Mohankumar, Guruprasad Balachandran, Murugan Kaliyamoorthy, Barathiraja Rajendran, and Rajendiran Gopal. "Optimization on Material Removal Rate and Surface Roughness of Stainless Steel 304 Wire Cut EDM by Response Surface Methodology." Advances in Materials Science and Engineering 2022 (August 29, 2022): 1–10. http://dx.doi.org/10.1155/2022/6022550.

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In this work, wire cut electrical discharge machining (WEDM) is used for the material removing processes; it is utilized for machining conductive parts where it is required to produce complicated shapes, new profiles, new geometry, new product development, and high-accuracy components. This machining process is best suitable for high-end applications such as aerospace, automations, automobile, and medical devices. At present, most of the industrial sectors choose the WEDM process because it is used to develop products in a very short development cycle and at a better economic rate. In this paper, the selected complex geometry of the metal sample was eroded away from the wire during the WEDM process, which eliminates mechanical tensions during machining. The effect of different WEDM operation variables set as wire speed, wire tension, discharge current, dielectric flow rate, and pulse on and off time on the parameter, stainless steel 304 material removing rate (MRR) using RSM, has been studied. The MRR will be maximized if the optimum sets of operational variations are used and also achieve a superior surface finish.

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Nur, Rusdi, M. Muas, Apollo, and Syah Risal. "Effect of Current and Wire Speed on Surface Roughness in the manufacturing of Straight Gear using Wire-cut EDM Process." IOP Conference Series: Materials Science and Engineering 619 (October 25, 2019): 012002. http://dx.doi.org/10.1088/1757-899x/619/1/012002.

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Rajmohan, K., and A. Senthil Kumar. "Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS." International Journal of Advanced Manufacturing Technology 93, no. 1-4 (March 19, 2016): 187–201. http://dx.doi.org/10.1007/s00170-016-8615-3.

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Muley, Mahesh. "Optimization of Wire Cut Electro Discharge Machining Process Parameters for Aluminium 6082 by using Taguchi Technique." International Journal for Research in Applied Science and Engineering Technology 9, no. 12 (December 31, 2021): 2257–62. http://dx.doi.org/10.22214/ijraset.2021.39723.

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Abstract: The manufacturing industry is changing very drastically in all the aspect regarding the manufacturing technology as well as the quality concern as per as the quality is considered. Quality is becoming a significant trend in todays growing automobile industry. In the field of metal cutting operations, the surface roughness is becoming more dominant parameter as per as the quality of the component is considered. Electrical discharge machining is becoming a most powerful non conventional machining which is being widely used in the field of machining. Most specifically our work was conducted on the electrical discharge wire cut machining for achieving the desired surface roughness (Ra) and adequate material removal rate (MRR). The input parameter for our research work were selected as Peak current, pulse on time & pulse off time while the output parameter was selected as MRR and the surface roughness. Aluminum 6082 Grade material is used as a specimen and the research methodology implemented for the research work is taguchi and Anova. Keywords: Wire cut EDM, Taguchi, MRR surface roughness, Anova.

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Vijaya Babu, T., and J. S. Soni. "Investigation of process parameters optimization in die-sinking and wire cut EDM to improve process performance using taguchi technique." Materials Today: Proceedings 5, no. 13 (2018): 27088–93. http://dx.doi.org/10.1016/j.matpr.2018.09.014.

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Oniszczuk-Świercz, Dorota, Rafał Świercz, and Štefan Michna. "Evaluation of Prediction Models of the Microwire EDM Process of Inconel 718 Using ANN and RSM Methods." Materials 15, no. 23 (November 23, 2022): 8317. http://dx.doi.org/10.3390/ma15238317.

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Precise machining of micro parts from difficult-to-cut materials requires using advanced technology such as wire electrical discharge machining (WEDM). In order to enhance the productivity of micro WEDM, the key role is understanding the influence of process parameters on the surface topography and the material’s removal rate (MRR). Furthermore, effective models which allow us to predict the influence of the parameters of micro-WEDM on the qualitative effects of the process are required. This paper influences the discharge energy, time interval, and wire speed on the surface topography’s properties, namely Sa, Sk, Spk, Svk, and MRR, after micro-WEDM of Inconel 718 were described. Developed RSM and ANN model of the micro-WEDM process, showing that the discharge energy had the main influence (over 70%) on the surface topography’s parameters. However, for MRR, the time interval was also significant. Furthermore, a reduction in wire speed can lead to a decrease in the cost process and have a positive influence on the environment and sustainability of the process. Evaluation of developed prediction models of micro-WEDM of Inconel 718 indicates that ANN had a lower value for the relative error compared with the RSM models and did not exceed 4%.

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Divya, Marelli, N. Sateesh, B. Ch Nookaraju, A. Anitha Lakshmi, and Subbiah Ram. "Multi performance optimisation of wire-cut EDM process parameters of Incoloy 800 alloy using grey relational analysis." Materials Today: Proceedings 44 (2021): 2416–20. http://dx.doi.org/10.1016/j.matpr.2020.12.464.

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Reddy, A. Damodara. "Optimization of Surface Roughness and Kerf Width Parameters in Wire Cut EDM Process through Response Surface Methodology." International Journal for Research in Applied Science and Engineering Technology V, no. XI (November 23, 2017): 2762–70. http://dx.doi.org/10.22214/ijraset.2017.11381.

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Journal articles on the topic 'WIRE-CUT EDM PROCESS'

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