Electrical discharge machining of 6061 aluminium alloy

The wire electrical discharge machining（EDM） of 6061 aluminium alloy in terms of material removal rate,kerf/slit width,surface finish and wear of electrode wire for different pulse on time and wire tension was studied.Eight experiments were carried out in a wire EDM machine by varying pulse on time and wire tension.It is found that the material removal rate increases with the increase of pulse on time though the wire tension does not affect the material removal rate.It seems that the higher wire tension facilitates steady machining process,which generates low wear in wire electrode and better surface finish.The surface roughness does not change notably with the variation of pulse on time.The appearance of the machined surfaces is very similar under all the machining conditions.The machined surface contains solidified molten material,splash of materials and blisters.The increase of the pulse on time increases the wear of wire electrode due to the increase of heat input.The wear of wire electrode generates tapered slot which has higher kerf width at top side than that at bottom side.The higher electrode wear introduces higher taper.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Wire electric discharge machining characteristics of titanium nickel shape memory alloy

Ti Ni shape memory alloys（SMAs） have been normally used as the competent elements in large part of the industries due to outstanding properties, such as super elasticity and shape memory effects. However, traditional machining of SMAs is quite complex due to these properties. Hence, the wire electric discharge machining（WEDM） characteristics of Ti Ni SMA was studied. The experiments were planned as per L27 orthogonal array to minimize the experiments, each experiment was performed under different conditions of pulse duration, pulse off time, servo voltage, flushing pressure and wire speed. A multi-response optimization method using Taguchi design with utility concept has been proposed for simultaneous optimization. The analysis of means（ANOM） and analysis of variance（ANOVA） on signal to noise（S/N） ratio were performed for determining the optimal parameter levels. Taguchi analysis reveals that a combination of 1 μs pulse duration, 3.8 μs pulse off time, 40 V servo voltage, 1.8×105 Pa flushing pressure and 8 m/min wire speed is beneficial for simultaneously maximizing the material removal rate（MRR） and minimizing the surface roughness. The optimization results of WEDM of Ti Ni SMA also indicate that pulse duration significantly affects the material removal rate and surface roughness. The discharged craters, micro cracks and recast layer were observed on the machined surface at large pulse duration.

Influence of Input Factors on Surface Roughness and Material Removal Speed when Wire-EDM a Hardened SKD11 Steel Curve Profile

The goal of this research is to identify the best set of process machining parameters for wire-EDM(Electrical Discharge Machining)cutting of hardened SKD11 steel when machining a curve profile.The multi-objective function includes reducing surface roughness and increasing MRR(Material Removal Rate).The optimization process is prepared by using Taguchi method coupled Grey Relational Analysis.The obtained results revealed that Toff has the greatest influence on the average grey value(48.30%),followed by the influence of WF(Wire Feed,15.99%),VM(Cutting Voltage,9.33%),SV(Server Voltage,5.05%),Ton(Pulse on Time,1.81%),while SPD(Cutting Speed)has a negligible effect(0.89%).Moreover,using the optimal set of machining parameters generates in surface roughness of 1.25399mm and MRR of 26.5562 mm^(2)/min.The verification experiment and Anderson-Darling method demonstrate the validity of the proposed model,which can be utilized for estimating surface roughness and MRR.

FOUR-AXIS WIRE-EDM SIMULATION OF COMPLICATED MODELS

In the verification of wire electrical discharge machining （EDM）, the motion and the performance of the wire-EDM system are analyzed. The maximum inclining angle of the wire is calculated. The relevant judgment methods are used for the collision between the wire, the fixture, and the machining table. In the wire-EDM simulation, the generated solid model can he used to investigate programming results and to check the machining accuracy. The generation algorithm for the solid model in the simulation is solved based on Boolean operations. The wire swept volume for each cutting step is united to form the entire wire swept volume. Through Boolean subtraction between the stock model and the entire wire swept volume, the solid model in the wire-EDM simulation is generated. The method is also suitable for the wire path intersection occurred in cutting cone-shaped models. Finally, experiments are given to prove the method.

Electrical Discharge Machining of Al2024-65 vol%SiC Composites

In the present work, the wire electrical discharge machining（WEDM） process of the 65 vol% SiCp/2024 Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined composite was characterized by scanning electron microscope, the average surface roughness（Ra）, X-ray diffraction, X-ray photoelectron spectroscopy and transmission electron microscopy（TEM） techniques. Three zones from the surface to the interior（melting zone, heat affected zone and un-affected zone） were found in the machined composites, while the face of SiC particles on the surface toward the outside was ‘‘cut＇＇ to be flat. Increase in Al and Si but decrease in C and O were observed in the core areas of the removed particles. Si phase, which was generated due to the decomposition of SiC, was detected after the WEDM process. The irregular and spherical particles were further observed by TEM. Based on the microstructure observation, it is suggested that the machining mechanism of 65 vol% SiCp/2024 Al composite was the combination of the melting of Al matrix and the decomposition of SiC particles.

WEDM oriented micro gear design and mesh simulation

For the design of gears manufactured with wire electrical discharge machining （WEDM） technology, determination of the primary gear parameters is discussed considering the characteristics of the machining method. Some constraint conditions on gear parameters are abnegated, which makes micro gear design more flexible. Based on gear mesh theory, the algorithm of generating gear tooth profiles is studied, which includes involute and non-involute curve segments. The phenomena of tooth profile interferences during gear mesh are analyzed, and a gear mesh simulation algorithm is designed. Based on ACIS, the WEDM oriented software for the design and mesh simulation of micro gears is developed, by which the modeling, mesh simulation and interference check can be implemented. An experiment is carried out to design and manufacture a pair of micro involute gears, and the proposed method is proved feasible.

Analysis and optimization of sustainable machining of AISI O1 tool steel by the wire-EDM process

Wire electrical discharge machining(wire-EDM)is an energy-intensive process,and its success relies on a correct selection of cutting parameters.It is vital to optimize energy consumption,along with productivity and quality.This experimental study optimized three parameters in wire-EDM:pulse-on time,servo voltage,and voltage concerning machining time,electric power,total energy consumption,surface roughness,and material removal rate.Two different plate thicknesses(15.88 mm and 25.4 mm)were machined.An orthogonal array,signal-to-noise ratio,and means graphs,and an analysis of vari-ance(ANOVA),determine the effects and contribution of cutting parameters on responses.Pulse-on time is the most significant factor for almost all variables,with a percentage of contribution higher than 50%.Multi-objective optimization is conducted to accomplish a concurrent decrease in all variables.A case study is proposed to compute carbon dioxide(CO_(2))tons and electricity cost in wire-EDM,using cutting parameters from multi-objective optimization and starting values commonly employed to cut that tool steel.A sustainable manufacturing approach reduced 5.91%of the electricity cost and CO_(2)tons when machining the thin plate,and these responses were diminished by 14.09%for the thicker plate.Therefore,it is possible to enhance the sustainability of the process without decreasing its productivity and quality.

Machine-vision-based electrode wear analysis for closed loop wire EDM process control

The purpose of this study was to develop a closed-loop machine vision system for wire electrical discharge machining(EDM)process control.Excessive wire wear leading to wire breakage is the primary cause of wire EDM process failures.Such process interruptions are undesirable because they affect cost efficiency,surface quality,and process sustainability.The developed system monitors wire wear using an image-processing algorithm and suggests parametric changes according to the severity of the wire wear.Microscopic images of the wire electrode coming out from the machining zone are fed to the system as raw images.In the proposed method,the images are preprocessed and enhanced to obtain a binary image that is used to compute the wire wear ratio(WWR).The input parameters that are adjusted to recover from the unstable conditions that cause excessive wire wear are pulse off time,servo voltage,and wire feed rate.The algorithm successfully predicted wire breakage events.In addition,the alternative parametric settings proposed by the control algorithm were successful in reducing the wire wear to safe limits,thereby preventing wire breakage interruptions.

Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm

Machining of shape memory alloys(SMAs)without losing the shape memory effect could immensely extend their applications.Herein,the wire electric discharge machining process was used to machine NiTi—a shape memory alloy.The experimental methodology was designed using a Box-Behnken design approach of the response surface methodology.The effects of input variables including pulse on time,pulse off time,and current were investigated on the material removal rate,surface roughness,and microhardness.ANOVA tests were performed to check the robustness of the generated empirical models.Optimization of the process parameters was performed using a newly formulated,highly efficient heat transfer search algorithm.Validation tests were conducted and extended for analyzing the retention of the shape memory effect of the machined surface by differential scanning calorimetry.In addition,2D and 3D Pareto curves were generated that indicated the trade-offs between the selected output variables during the simultaneous output variables using the multi-objective heat transfer search algorithm.The optimization route yielded encouraging results.Single objective optimization yielded a maximum material removal rate of 1.49 mm^(3)/s,maximum microhardness 462.52 HVN,and minimum surface roughness 0.11μm.The Pareto curves showed conflicting effects during the wire electric discharge machining of the shape memory alloy and presented a set of optimal non-dominant solutions.The shape memory alloy machined using the optimized process parameters even indicated a shape memory effect similar to that of the starting base material.

Prediction and analysis of process failures by ANN classification during wire-EDM of Inconel 718

Wire breakages and spark absence are two typical machining failures that occur during wire electric discharge machining(wire-EDM),if appropriate parameter settings are not maintained.Even after several attempts to optimize the process,machining failures cannot be eliminated completely.A n offline classification model is presented herein to predict machining failures.The aim of the current study is to develop a multiclass classification model using an artificial neural network(ANN).The training dataset comprises 81 full factorial experiments with three levels of pulse-on time,pulse-off time,servo voltage,and wire feed rate as input parameters.The classes are labeled as normal machining,spark absence,and wire breakage.The model accuracy is tested by conducting 20 confirmation experiments,and the model is discovered to be 95%accurate in classifying the machining outcomes.The effects of process parameters on the process failures are discussed and analyzed.A microstructural analysis of the machined surface and worn wire surface is conducted.The developed model proved to be an easy and fast solution for verifying and eliminating process failures.

Effect of assisted transverse magnetic field on distortion behavior of thin-walled components in WEDM process

Machining performance of thin-walled components made by aeronautical difficult-toprocess materials is a significant issue in the aviation manufacturing industry.Although wire electric discharge machining-low speed(WEDM-LS)is one of typical non-contact machining processes without macro cutting force,which does well in removing hardness and brittleness materials via pulsed discharge at high temperature,but few researchers have studied the thermal distortion behavior leading to a considerable geometric error in the WEDM-LS of thin-walled components.In this paper,a transverse magnetic field assisted method is applied for affecting the uniformity of discharge point distribution so as to reduce the distortion in WEDM-LS processing thin-wall component.First,the generation mechanism of this new distortion behavior and the impact mechanism of transverse magnetic field(TMF)on distortion are demonstrated by theoretical analysis.In order to further figure out the distortion behavior in the TMF-WEDM process,a new thermophysical model considering the discharge point distribution is established to simulate temperature field,residual stress field and distortion profiles.Then a large number of Taguchi experiments are carried out to investigate the influences of process parameters including pulse discharge energy(pulse on time,pulse off time,and current)and magnetic field strength on distortion in WEDM-LS.To comparatively analyze simulated and experimental results,the accuracy of established thermophysical model is verified within a relative error of 18.38%in distortion.Moreover,it can be revealed that transverse magnetic field contribute to significantly improve the longitudinal distribution uniformity with maximum increase of 12.32%at magnetic field strength:0.15 T,leading to significant reductions of 32.77%in distortion and 22.68%in recast layer.Eventually,we also presented the variation of residual stress and recast layer along thickness direction under different distortion behavior,which are in good agreement with that of distortion behavior.