Cutting Ability of D2 Steel w.r.t Wire Materials in WIRE-EDM
Keywords:
Optimization, ANOVA, MRR, Wire surface roughness; Wire materials: brass and zinc.Abstract
The wire cut industry is using plain brass wire as electrodes in wire electrical discharge machining (WEDM) for a long period. An attempt is made to find out levels of process parameters for high material removal rate (MRR) and low surface roughness (SR) in case of plane wire vis–a-vis the zinc-coated brass wire, and to compare the result for better understanding of manufacturing process. In this experimental study, the four process variables selected are pulse on time (TON), pulse off time (TOFF), peak current (IP) and servo voltage (Sv). Taguchi’s L18 mixed OA is used for experimentation with one repetition. The optimum levels for high material removal rate and low surface roughness are obtained by single-response optimization technique. ANOVA and S/N ratio techniques are applied to find significant factors and plot comparison graphs. The present study shows that zinc-coated brass wire exhibits better machining qualities than plain brass wire with high MRR and low surface roughness. Confirmatory experiments show the significant increase in MRR and surface finish by both wires for optimal levels of parameters.
References
[2]. Abinesh P, Varatharajan K, Kumar GS. Optimization of process parameters influencing MRR, surface roughness and electrode wear during machining of titanium alloys by WEDM. International Journal of Engineering Research and General Science 2014; 2(1): 719-29.
[3]. Vates UK, Singh NK, Singh RV. Modelling of process parameters on D2 steel using wire electrical discharge machining with combined approach of RSM and ANN. International Journal of Scientific & Engineering Research 2014; 5(1): 2026-35.
[4]. Huang JT, Liao YS. Optimization of machining parameters of WEDM based Grey relational and statistical analyses. International Journal of Production Research 2003; 41(8): 1707-20.
[5]. Ramakrishnan R, Karunamoorthy L. Multi response optimization of wire EDM operations using robust design of experiments. International Journal of Advance Manufacturing Technology 2006; 29, 105-12.
[6]. Mahapatra SS, Patnaik A. Parametric optimization of WEDM process using Taguchi method. Journal of the Brazilian Society of Mechanical Science and Engineering 2006; 27(4): 422-29.
[7]. Dhobe MM, Chopde IK, Gogte CL. Effect of heat treatment and process parameters on surface roughness in WEDM. International Journal of Mechanical Engineering and Robotics Research 2013; 2(2): 275-81.
[8]. Maan V, Chaudhary A. Optimization of WEDM of D-2 steel using response surface methodology. International Journal of Engineering Research and Application 2013; 3(3): 206-16.
[9]. Ikram A, Mufti NA, Saleem MQ et al. Parametric optimization for surface roughness, kerf and MRR in WEDM using Taguchi design of experiment. Journal of Mechanical Science and Technology 2013; 23(7): 2133-41.
[10]. Patil PA, Wahgmare CA. Optimization of process parameters in WEDM using response surface methodology. Proceedings of 10th IRF International Conference 2014; 110-15.
[11]. Bhatia A, Kumar S, Kumar P. A study to achieve minimum surface roughness in wire EDM. International Conference on Advances in Manufacturing and Materials Engineering AMME 2014; 2560-66.
