Multi-response Optimization and Effect of Alumina Mixed with Dielectric Fluid on WEDM Process of Ti6Al4V

2022 ◽  
pp. 277-287
Author(s):  
Jay Vora ◽  
Nisarg Prajapati ◽  
Smit Patel ◽  
Shlok Sheth ◽  
Aditya Patel ◽  
...  
Keyword(s):  
Dielectric Fluid ◽  
Response Optimization ◽  
Wedm Process

Multi-Response Optimization of Micro-WEDM Process Parameters of Ti49.4-Ni50.6 Shape Memory Alloy for Orthopedic Implant Application

2018 ◽  
Vol 1150 ◽  
pp. 1-21
Author(s):  
Adik M. Takale ◽  
Nagesh K. Chougule ◽  
Preetam H. Selmokar ◽  
M.G. Gawari
Keyword(s):  
Shape Memory Alloy ◽  
Shape Memory ◽  
Process Parameters ◽  
Removal Rate ◽  
Orthopedic Implant ◽  
Wire Tension ◽  
Response Optimization ◽  
Micro Wedm ◽  
Wedm Process ◽  
Wire Feed

The present work deals with the optimization of micro-WEDM process parameters for machining Ti49.4-Ni50.6 shape memory alloy (SMA) for orthopedic implant application. Effect of micro-WEDM parameters viz. Gap voltage, capacitance, wire feed and wire tension on the response variables such as material removal rate, surface roughness, kerf width and dimensional deviation is determined. As Ti-Ni SMA has fascinating properties and bio-compatibility, have been considered for present work. Nine experiments have been performed on micro-WEDM based on an orthogonal array of Taguchi method. Subsequently, the grey relational analysis (GRA) method is applied to determine an optimal set of process parameters. It is observed that optimized set of parameters A3B3C3D1 viz. 140 V gap voltage, 0.4 µF capacitance, wire feed 30 µm/sec and 30% of wire tension determined by using GRA offers maximum MRR and minimum SR, KW and DD. From the Analysis of Variance, it is seen that the process parameter capacitance is the most significant parameter for multi-response optimization with a percentage contribution of 77.91%. Young’s modulus also checked for biocompatibility. Also, SEM images are taken to confirm the results offering better surface quality. Heat treatment process like annealing is found to be the most suitable to recover shape memory effect of WEDMed samples.

Multi-Response Optimization of CNC WEDM Process Parameters for Machining Titanium Alloy Ti 6AI-4V Using Response Surface Methodology (RSM)

2014 ◽  
Vol 541-542 ◽  
pp. 354-358 ◽  
Author(s):  
C. Nandakumar ◽  
B. Mohan
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Titanium Alloy ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Response Optimization ◽  
Wedm Process

This research deals with the multi-response optimization of CNC WEDM process parameters for machining titanium alloy Ti 6AI-4V using Response Surface Methodology (RSM) to achieve higher Material Removal Rate (MRR) and lower surface roughness (Ra). The process parameters of CNC WEDM namely pulse-on time (TON), pulse-off time (TOFF) and wire feed rate (WF) were optimized to study the responses in terms of material removal rate and surface roughness. The surface plot and the contour plots were generated between the process parameters and the responses using MINITAB software. The results show that the Response surface methodology (RSM) is a powerful tool for providing experimental diagrams and statistical-mathematical models to perform the experiments appropriately and economically.

scholarly journals Analysis of WEDM Process Parameters on Surface Roughness and Kerf using Taguchi Method

2017 ◽  
Vol 2 (4) ◽  
pp. 103-109 ◽  
Author(s):  
Asfana Banu ◽  
Mazilah Abu Bakar ◽  
Mohammad Yeakub Ali ◽  
Erry Y. T. Adesta
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Machining Parameters ◽  
Wire Tension ◽  
Wedm Process ◽  
Off Time

In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap. 

scholarly journals Multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining

2020 ◽  
Vol 12 (10) ◽  
pp. 168781402096758
Author(s):  
Tina Chaudhary ◽  
Arshad Noor Siddiquee ◽  
Arindam Kumar Chanda ◽  
Mustufa Haider Abidi ◽  
Abdulrahman Al-Ahmari
Keyword(s):  
Surface Roughness ◽  
Ethylene Glycol ◽  
Process Parameters ◽  
Dielectric Fluid ◽  
Alumina Powder ◽  
Response Factors ◽  
Machining Time ◽  
Wire Tension ◽  
Demineralized Water ◽  
Response Optimization

Generally, gear is an essential component in various electro-mechanical devices, but its manufacturing at the micro-level is challenging. The non-conventional manufacturing processes, such as electro-discharge machining (EDM), is suitable in gear fabrication. Although miniature gears have strict accuracy requirements, the optimization of the EDM process parameters, especially for advanced materials and alloys, is critical. In this paper, Nimonic alloy miniature gears are manufactured using wire-EDM and the effect of process parameters, such as peak current, pulse-off (POFF) time, pulse-on (PON) time, wire tension, and dielectric fluid on the response factors are analyzed. The primary response factors, such as surface roughness, machining time, material removal rate, kerf width (KW), surface microhardness, and depth of microhardness are considered. Also, different dielectric fluids are prepared, which include ethylene glycol mixed demineralized water, oxygen mixed demineralized water, ethylene glycol and alumina powder mixed demineralized water, and ethylene glycol alumina powder and oxygen mixed demineralized water. Furthermore, the effect of process parameters on the multi-response using Pareto ANOVA has been analyzed. The results demonstrate that ethylene glycol mixed demineralized water, as a dielectric fluid, is the most influencing parameter to reduce the surface roughness, machining time, KW, and improve micro-hardness. Thus, dielectric fluid is an essential factor obtained from multi-response optimization followed by peak current, POFF time, wire tension, and PON time.

scholarly journals Study on Effect of Blended Powder Mixed Dielectric Fluids in Wire EDM Process

2021 ◽  
Vol 9 (VIII) ◽  
pp. 589-599
Author(s):  
Viraj Chavan
Keyword(s):  
Removal Rate ◽  
High Surface ◽  
Dimensional Accuracy ◽  
Dielectric Fluid ◽  
Optimum Level ◽  
Workpiece Material ◽  
Dielectric Fluids ◽  
Wire Electric Discharge Machining ◽  
Materials Used ◽  
Wedm Process

Wire Electric Discharge Machining (WEDM) process is used for machining various materials used in applications that require dimensional accuracy, high surface finish and have intricate shapes. This work includes the study of WEDM process when dielectric fluid is mixed with combination of two metallic powders viz. Silicon Carbide and Aluminium Oxide. The effect of this powder mixing on Material Removal Rate (MRR) and Surface Roughness (SR) is being analysed and optimum level of control parameters is found out. AISI D3 which is also called as die steel is used as workpiece material. Distilled water (30 TDS) is used as dielectric fluid and Zinc cozted Brass wire (CuZn37) is used as wire electrode. DOE is done using Taguchi. Significant parameters are found out using ANNOVA. Lastly GRA is used to find optimum set of parameters.

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