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This work intended to improve the precision and machining efficiency of Magnesium alloy (Mg-Li-Sr) using Wire electrical discharge machining (WEDM). Mg-Li-Sr alloy is prepared through inert gas assisted stir casting route. Taguchi approach is used for experimental design for WEDM parameter such as pulse OFF time, pulse ON time, wire feed rate, servo voltage and current. L27 orthogonal array is considered to understand the influence of control parameter such as Kerf Width (KW), Roughness of the surface (Ra), Material Removal Rate (MRR). Integration of the CRITIC (Criteria Importance Through Intercriteria Correlation) -WASPAS (Weighted Aggregated Sum Product Assessment) multi-objective optimization method with Artificial Neural Network (ANN) modelling with different network structure for prediction and optimization is a novel approach that significantly improves prediction accuracy and machining outcomes. The developed ANN model with better R2 value of 99.9 % has better ability for prediction while correlated with formulated conventional regression equation. The error percentages identified through confirmation tests for regression and ANN models are Ra - 8.5 % and 3.4 %, MRR - 5.9 % and 2.8 %, KW - 6.7 % and 2.2 % respectively. Optimal output response attained by CRITIC-WASPAS approach yields surface roughness of 4.62 µm, material removal rate of 0.073 g/min and kerf width of 0.388 µm.
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Electrical Discharge Machining (EDM) is a non-conventional machining technique, capable of processing any kind of conductive material. Recently, it has been successfully utilized for producing hydrophobic characteristics in inherently hydrophilic metallic materials. In this work, Wire Electrical Discharge Machining (WEDM) was utilized for producing hydrophobic characteristics on the surface of the aluminum alloy 6082, and various parameters that can affect wettability were investigated. Adopting an orthogonal Taguchi approach, the effects of the process parameter values of peak current, pulse-on time, and gap voltage on the contact angles of the machined surfaces were investigated. After machining, all samples were observed to have obtained hydrophobic properties, reaching contact angles up to 132°. The peak current was identified as the most influential parameter regarding the contact angle, while the gap voltage was the less influential parameter. A contact angle variation of 30° was observed throughout different combinations of machining parameters. Each combination of the machining parameters resulted in a distinct surface morphology. The samples with moderate roughness values (3.4 µm > Sa > 5.7 µm) were found to be more hydrophobic than the samples with high or low values, where the contact angle was measured under 115°. In addition, the finite element modeling of the experimental setup, with parametric surfaces of uniform random and Perlin noise types of roughness, was implemented. Time dependent simulations coupling phase field and laminar flow for the modelingof the wetting of surfaces with different surface roughness characteristics showed that an increase in the Sa roughness and total wetted area can lead to an increase in the contact angle. The combination of experimental and computational results suggests that the complexity of the wettability outcomes of aluminum alloy surfaces processed with WEDM lies in the interplay between variations of the surface chemical composition, roughness, micro/nano morphology, and the surface capability of forming a composite air/water interface.
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When machining high-speed steels (HSS) with micro-wire electrical discharge machining (micro-WEDM), high surface quality is achieved as standard. The value of the roughness parameter Ra is less than 0.2 µm. However, the problem is the performance of the electroerosion process (MRR), which is low. This problem is related to the mechanical and physical properties of the HSS in combination with the setting of the main technological parameters (MTP). The proposed solution to eliminate this problem relies on the selection of proper procedures for the determination of optimization criteria in relation to Ra and MTP, with the inclusion of properties of the machined material. The solution consisted in the identification of four significant physical (ρ, κ) and mechanical (Rm, HRC) indicators of HSS properties, on the basis of which a suitable combination of the process output parameters Ra and MRR can be determined through established mathematical regression models using simulation and optimization. In the next step, the proper values of the MTP output process parameter settings, which correspond to the optimized output parameters Ra and MRR during machining of HSS by micro-WEDM technology, were then obtained by the same approach.
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In this research, a comparison between two methods of grinding and WEDM and the chip formation of each form tool was studied through a set of designs of experiments. A multi-functional form tool with different cutting-edge shapes was designed to compare different production methods, and a grinding machine and a five-axis wire-cutting machine were made. The form tools by the wire cutting method were made with three different machining states, rough, semi-finish, and finish. The results of the experimental test showed that the chip formation of the finished surface of the wire cut tool was close to the ground tools. Additionally, the tool life in wear generation was assessed, revealing that the tool generated through the wire-cutting method with three passes exhibited superior performance compared to alternative approaches. Furthermore, employing the wire-cutting technique with high surface finishing yielded optimal outcomes for producing form-cutting tools featuring complex profiles.
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Nimonic alloy is difficult to machine using traditional metal cutting techniques because of the high cutting forces required, poor surface integrity, and tool wear. Wire electrical discharge machining (WEDM) is used in a number of sectors to precisely machine complex forms of nickel-based alloy in order to attempt to overcome these challenges and provide high-quality products. The Taguchi-based design of experiments is utilized in this study to conduct the tests and analyses. The gap voltage (GV), pulse-on time (Ton), pulse-off time (Toff), and wire feed (WF), are considered as the variable process factors. GRA is used for the WEDM process optimization for the Nimonic-263 superalloy, which has multiple performance qualities including the material removal rate (MRR), surface roughness (SR), and kerf width (KW). ANOVA analysis was conducted to determine the factors' importance and influence on the output variables. Multi objective optimization techniques were employed for assessing the machining performances of WEDM using GRA. The ideal input parameter combinations were determined to be a gap voltage (GV) of 40 V, a pulse-on time (Ton) of 8 µs, a pulse-off time (Toff) of 16 µs, and a wire feed (WF) of 4 m/min. A material removal rate of 8.238 mm3/min, surface roughness of 2.83 µm, and kerf width of 0.343 mm were obtained. The validation experiments conducted also demonstrated that the predicted and experimental values could accurately forecast the responses.
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The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed.
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Machining titanium alloy (Ti6Al4V) used in orthopedic implants via conventional metal cutting processes is challenging due to excessive cutting forces, low surface integrity, and tool wear. To overcome these difficulties and ensure high-quality products, various industries employ wire electrical discharge machining (WEDM) for precise machining of intricate shapes in titanium alloy. The objective is to make WEDM machining parameters as efficient as possible for machining the biocompatible alloy Ti6Al4Vusing Box-Behnken design (BBD) and nondominated sorting genetic algorithm II (NSGA II). A quadratic mathematical model is created to represent the productivity and the quality factor (MRR and surface roughness) in terms of varying input parameters, such as pulse active (Ton) time, pulse inactive (Toff) time, peak amplitude (A) current, and applied servo (V) voltage. The established regression models and related prediction plots provide a reliable approach for predicting how the process variables affect the two responses, namely, MRR and SR. The effects of four process variables on both the responses were examined, and the findings revealed that the pulse duration and voltage have a major influence on the rate at which material is removed (MRR), whereas the pulse duration influences quality (SR). The tradeoff between MRR and SR, when significant process factors are included, emphasizes the need for a reliable multi-objective optimization method. The intelligent metaheuristic optimization method named nondominated sorting genetic algorithm II (NSGA II) was utilized to provide pareto optimum solutions in order to achieve high material removal rate (MRR) and low surface roughness (SR).
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This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.
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Any industry that manufactures dies, punches, molds, and machine components from difficult-to-cut materials, such as Inconel, titanium, and other super alloys, largely relies on wire electrical discharge machining (WEDM). In the current study, the effect of the WEDM process parameters on Inconel 600 alloy with untreated zinc and cryogenically treated zinc electrodes was investigated. The controllable parameters included the current (IP), pulse-on time (Ton), and pulse-off time (Toff), whereas the wire diameter, workpiece diameter, dielectric fluid flow rate, wire feed rate, and cable tension were held constant throughout the experiments. The significance of these parameters on the material removal rate (MRR) and surface roughness (Ra) was established using the analysis of the variance. The experimental data acquired using the Taguchi analysis were used to analyze the level of influence of each process parameter on a particular performance characteristic. Their interactions with the pulse-off time were identified as the most influential process parameter on the MRR and Ra in both cases. Furthermore, a microstructural analysis was also performed via scanning electron microscopy (SEM) to examine the recast layer thickness, micropores, cracks, depth of metal, pitching of metal, and electrode droplets over the workpiece surface. In addition, energy-dispersive X-ray spectroscopy (EDS) was also carried out for the quantitative and semi-quantitative analyses of the work surface and electrodes after machining.
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Its unexcelled mechanical and physical properties, in addition to its biocompatibility, have made stainless steel 304 a prime candidate for a wide range of applications. Among different manufacturing techniques, electrical discharge machining (EDM) has shown high potential in processing stainless steel 304 in a controllable manner. This paper reports the results of an experimental investigation into the effect of the process parameters on the obtainable surface roughness and material removal rate of stainless steel 304, when slotted using wire EDM. A full factorial design of the experiment was followed when conducting experimental trials in which the effects of the different levels of the five process parameters; applied voltage, traverse feed, pulse-on time, pulse-off time, and current intensity were investigated. The geometry of the cut slots was characterized using the MATLAB image processing toolbox to detect the edge and precise width of the cut slot along its entire length to determine the material removal rate. In addition, the surface roughness of the side walls of the slots were characterized, and the roughness average was evaluated for the range of the process parameters being examined. The effect of the five process parameters on both responses were studied, and the results revealed that the material removal rate is significantly influenced by feed (p-value = 9.72 × 10-29), followed by current tension (p-value = 6.02 × 10-7), and voltage (p-value = 3.77 × 10-5), while the most significant parameters affecting the surface roughness are current tension (p-value = 1.89 × 10-7), followed by pulse-on time (1.602 × 10-5), and pulse-off time (0.0204). The developed regression models and associated prediction plots offer a reliable tool to predict the effect of the process parameters, and thus enable the optimizing of their effects on both responses; surface roughness and material removal rate. The results also reveal the trade-off between the effect of significant process parameters on the material removal rate and surface roughness. This points out the need for a robust multi-objective optimization technique to identify the process window for obtaining high quality surfaces while keeping the material removal rate as high as possible.
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A comparative study was conducted for the machining of two α/ß titanium alloys, namely Ti-6Al-4V (Ti64) and Ti-6Al-7Nb (Ti67), using wire electric discharge machining (WEDM). The influence of cutting speed and cutting mode on the machined surfaces in terms of surface roughness (Ra), recast layer (RL), and micro-hardness have been evaluated. Rough cut (RC) mode at a cutting speed of 50 µm/s resulted in thermal damage; Ra was equal to 5.68 ± 0.44 and 4.52 ± 0.35 µm for Ti64 and Ti67, respectively. Trim-cut mode using seven cuts (TRC-VII) at the same speed decreased the Ra to 1.02 ± 0.20 µm for Ti64 and 0.92 ± 0.10 µm for Ti67. At 100 µm/s, Ra reduced from 2.34 ± 0.28 µm to 0.88 ± 0.12 µm (Ti64), and from 1.42 ± 0.15 µm to 0.90 ± 0.08µm (Ti67) upon changing from TRC-III to TRC-VII. Furthermore, a thick recast layer of 30 ± 0.93 µm for Ti64 and 14 ± 0.68 µm for Ti67 was produced using the rough mode, while TRC-III and TRC-VII modes produced layers of 12 ± 1.31 µm and 5 ± 0.72 µm for Ti64 and Ti67, respectively. Moreover, rough cut and trim cut modes of WEDM played a significant role in promoting the surface hardness of Ti64 and Ti67. By employing the Response Surface Methodology, it was found that the machining mode followed by cutting speed and the interaction between them are the most influential parameters on surface roughness. Finally, mathematical models correlating machining parameters to surface roughness were successfully developed. The results strongly promote the trim-cut mode of WEDM as a promising machining route for two-phase titanium alloys.
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Nickel-based superalloys find their main use in missile engines, atomic devices, investigational aircraft, aerospace engineering, industrial applications, and automotive gas turbines, spacecraft petrochemical tools, steam power, submarines, and broader heating applications. These superalloys impose certain difficulties during the process fabrication owing to their levels of higher hardness. In the current study, the precise machining of Waspaloy was attempted through the wire electrical discharge machining (WEDM) technique. A multi-objective optimization has been performed, and the influence of multi-walled carbon nanotubes (MWCNTs) has been assessed using the passing vehicle search (PVS) algorithm. The effects of machining variables like current, Toff, and Ton were studied using the output measures of material removal rate (MRR), recast layer thickness (RLT), and surface roughness (SR). The Box-Behnken design was applied to generate the experimental matrix. Empirical models were generated which show the interrelationship among the process variables and output measures. The analysis of variance (ANOVA) method was used to check the adequacy, and suitability of the models and to understand the significance of the parameters. The PVS technique was executed for the optimization of MRR, SR, and RLT. Pareto fronts were derived which gives a choice to the user to select any point on the front as per the requirement. To enhance the machining performance, MWCNTs mixed dielectric fluid was utilized, and the effect of these MWCNTs was also analyzed on the surface defects. The use of MWCNTs at 1 g/L enhanced the performance of MRR, SR, and RLT by 65.70%, 50.68%, and 40.96%, respectively. Also, the addition of MWCNTs has shown that the machined surface largely reduces the surface defects.
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As a potential candidate for the next generation of high-temperature alloys, refractory high entropy alloys (RHEAs) have excellent mechanical properties and thermal stability, especially for high-temperature applications, where the processing of RHEAs plays a critical role in engineering applications. In this work, the wire electrical discharge machining (WEDM) performance of WNbMoTaZrx (x = 0.5, 1) RHEAs was investigated, as compared with tungsten, cemented carbide and industrial pure Zr. The cutting efficiency (CE) of the five materials was significantly dependent on the melting points, while the surface roughness (Ra) was not. For the RHEAs, the CE was significantly affected by the pulse-on time (ON), pulse-off time (OFF) and peak current (IP), while the surface roughness was mainly dependent on the ON and IP. The statistical analyses have shown that the CE data of RHEAs have relatively-smaller Weibull moduli than those for the Ra data, which suggests that the CE of RHEAs can be tuned by optimizing the processing parameters. However, it is challenging to tune the surface roughness of RHEAs by tailoring the processing parameters. Differing from the comparative materials, the WEDMed surfaces of the RHEAs showed dense spherical re-solidified particles at upper recast layers, resulting in larger Ra values. The proportion of the upper recast layers can be estimated by the specific discharge energy (SDE). Following the WEDM, the RHEAs maintained the main BCC1 phase, enriched with the W and Ta elements, while the second BCC2 phase in the Zr1.0 RHEA disappeared. Strategies for achieving a better WEDMed surface quality of RHEAs were also proposed and discussed.
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Several components are made from Al-Mg-based composites. MoS2 is used to increase the composite's machinability. Different weight percent (3, 4, and 5) of MoS2 are added as reinforcement to explore the machinability properties of Al-Mg-reinforced composites. The wire cut electrical discharge machining (WEDM) process is used to study the machinability characteristics of the fabricated Al-Mg-MoS2 composite. The machined surface's roughness and overcut under different process conditions are discussed. The evaluation-based distance from average solution (EDAS) method is used to identify the optimal setting to get the desired surface roughness and overcut. The following WEDM process parameters are taken to determine the impact of peak current, pulse on time, and gap voltage on surface roughness, and overcut. The WEDM tests were carried out on three different reinforced samples to determine the impact of reinforcement on surface roughness and overcut. The surface roughness and overcut increase as the reinforcement level increases, but the optimal parameters for all three composites are the same. According to EDAS analysis, I3, Ton2, and V1 are the best conditions. Furthermore, peak current and pulse on-time significantly influence surface roughness and overcut.
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Nitinol-shape memory alloys (SMAs) are widely preferred for applications of automobile, biomedical, aerospace, robotics, and other industrial area. Therefore, precise machining of Nitinol SMA plays a vital role in achieving better surface roughness, higher productivity and geometrical accuracy for the manufacturing of devices. Wire electric discharge machining (WEDM) has proven to be an appropriate technique for machining nitinol shape memory alloy (SMA). The present study investigated the influence of near-dry WEDM technique to reduce the environmental impact from wet WEDM. A parametric optimization was carried out with the consideration of design variables of current, pulse-on-time (Ton), and pulse-off-time (Toff) and their effect were studied on output characteristics of material removal rate (MRR), and surface roughness (SR) for near-dry WEDM of nitinol SMA. ANOVA was carried out for MRR, and SR using statistical analysis to investigate the impact of design variables on response measures. ANOVA results depicted the significance of the developed quadratic model for both MRR and SR. Current, and Ton were found to be major contributors on the response value of MRR, and SR, respectively. A teaching-learning-based optimization (TLBO) algorithm was employed to find the optimal combination of process parameters. Single-response optimization has yielded a maximum MRR of 1.114 mm3/s at Ton of 95 µs, Toff of 9 µs, current of 6 A. Least SR was obtained at Ton of 35 µs, Toff of 27 µs, current of 2 A with a predicted value of 2.81 µm. Near-dry WEDM process yielded an 8.94% reduction in MRR in comparison with wet-WEDM, while the performance of SR has been substantially improved by 41.56%. As per the obtained results from SEM micrographs, low viscosity, reduced thermal energy at IEG, and improved flushing of eroded material for air-mist mixture during NDWEDM has provided better surface morphology over the wet-WEDM process in terms of reduction in surface defects and better surface quality of nitinol SMA. Thus, for obtaining the better surface quality with reduced surface defects, near-dry WEDM process is largely suitable.
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In wire electrical discharge machining, due to the random distribution of the insulating SiC particles, frequent wire rupture, low machining efficiency and surface quality when the common brass wire electrode (BWE) is used to process high-volume content SiCp/Al composite often appears. To address this issue, this paper proposes a new preparation method of zinc coating and surface microstructure on wire electrodes (ZCSMWE). The preparation process of ZCSMWE includes casting, coating, annealing and plastic processing. The experimental results show that, compared with BWE, ZCSMWE can increase material removal rate (MRR) by 16.67%, reduce surface roughness (Ra) by 21.18% and reduce wire rupture under the same discharge parameters. The analysis of workpiece surface topography shows that ZCSMWE can significantly decrease the recast layer and microcrack on the machined surface. The improvement mechanism of ZCSMWE main includes: The low work function zinc can promote the forming of the discharge channel. The vaporization of low boiling temperature zinc can reduce the temperature of the discharge gap and promote the ejecting of workpiece material. In addition, the surface microstructure on ZCSMWE can make the discharge spark more uniformly distributed and increase the proportion of the effective discharge, which contributes to making the discharge crater on the workpiece and wire electrode shallower and more uniform. The surface microstructure on ZCSMWE can also effectively improve the dielectric circulation, which can promote discharge debris to be expelled out and reduce the temperature in the discharge gap. Then, the wire rupture and microcracks on the workpiece surface can be reduced.
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Titanium alloys with special macro-micro composite structures of directional hydrophobicity are difficult to prepare due to poor thermal conductivity and good corrosion resistance, inhibiting the wide engineering applications for aerospace, marine engineering, and biomedicine. To prepare macro-micro composite structures on the surface of titanium alloys and achieve directional hydrophobicity, the sub-millimeter structures with an edge width of 150 µm, a groove width of 250 µm, and a depth of 250 µm were fabricated on the titanium alloy by wire electrical discharge machining (WEDM) technology, and high voltage-induced weak electric arc machining (HV-µEAM) was used to fabricate micro-scale feature size micro-structures on the processed macro-structure edges. The influence of process parameters on the morphology of microstructures was studied experimentally. The smooth surface of the titanium alloy is isotropically hydrophilic, and its contact angle is 68°. After processing the macrostructure on the titanium alloy surface, it shows directional hydrophobicity after being modified by low surface energy materials. The macro-micro composite structure formed by HV-µEAM realizes a directional hydrophobic surface with contact angles (CA) of 140° (parallel direction) and 130° (perpendicular direction), respectively. This surface has been modified with low surface energy to achieve contact angles of 154° and 143°. The results of the abrasion resistance test show that under the load of 100 g, it retains directional hydrophobicity at a friction distance of 700 mm with 600# sandpaper. The existence of the sub-millimeter macrostructure is the reason for the directionality of surface hydrophobicity. The microstructure can realize the transformation of the titanium alloy surface from hydrophilic to hydrophobic. Under the combined effects of the macro and micro composite structure, the surface of the titanium alloy shows obvious directional hydrophobicity.
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In the present research, the AZ31 alloy is machined by wire-cut electric discharge machining (WEDM). The experiments were designed according to the Box-Behnken design (BBD) of response surface methodology (RSM). The input process variables, namely servo feed (SF), pulse on-time (Ton), servo voltage (SV), and pulse off-time (Toff), were planned by BBD, and experiments were performed to investigate the cutting rate (CR) and recast layer thickness (RCL). The analysis of variance (ANOVA) was performed to determine the influence of machining variables on response characteristics. The empirical models developed for CR and RCL were solved using Multi-Objective Particle Swarm Optimization (MOPSO). Pareto optimal front is used for the collective optimization of CR and RCL. The optimal solution suggested by the hybrid approach of RSM-MOPSO is further verified using a confirmation test on the random setting indicated by the hybrid algorithm. It is found that the minimum RCL (6.34 µm) is obtained at SF: 1700; SV: 51 V; Toff: 10.5 µs; and Ton: 0.5 µs. However, maximum CR (3.18 m/min) is predicted at SF: 1900; SV: 40 V; Toff: 7 µs; and Ton: 0.9 µs. The error percentage of ±5.3% between the experimental results and predicted solutions confirms the suitability of the proposed hybrid approach for WEDM of AZ31.
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Wire electrical discharge machining (WEDM) is an unconventional machining technology that can be used to machine materials with minimum electrical conductivity. The technology is often employed in the automotive industry, as it makes it possible to produce mold parts of complex shapes. Copper alloys are commonly used as electrodes for their high thermal conductivity. The subject of this study was creating mathematical models for the machining optimization of Ampcoloy 35 with different thicknesses (ranging from 5 to 160 mm with a step of 5 mm) using WEDM to improve the surface properties of the mold parts. The Box-Behnken type experiment was used with a total of 448 samples produced. The following machining parameters were altered over the course of the experiment: the pulse on and off time, discharge current, and material thickness. The cutting speed was measured, and the topography of the machined surfaces in the center and at the margins of the samples was analyzed. The morphology and subsurface layer were also studied. What makes this study unique is the large number of the tested thicknesses, ranging from 5 to 160 mm with a step of 5 mm. The contribution of this study to the automotive industry and plastic injection mold production is, therefore, significant. The regression models for the cutting speed and surface topography allow for efficient defect-free machining of Ampcoloy 35 of 5-160 mm thicknesses, both on the surface and in the subsurface layer.
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In the present work, an attempt has been made to study the influence of process parameters of the wire electric discharge machining (WEDM) process on the machining characteristics. The commercially pure titanium is machined by WEDM using brass wire as an electrode. The input parameters in this work were pulse on-time (Aon), pulse off-time (Aoff), servo voltage (SV) and wire tension (WT). On the other hand, dimensional accuracy (DA), average surface roughness (Ra) and maximum surface roughness (Rz) were chosen as the response parameters. The empirical relations developed for response characteristics were solved collectively using Evaluation Based on Distance from Average Solution (EDAS) and Particle Swarm Optimization (PSO). The optimized setting for minimizing the surface irregularities while machining titanium alloy on WEDM is predicted as Aon: 8 µs; Aoff: 13 µs; SV: 45 V; and WT: 8 N. Moreover, the predicted solution at the optimized parametric settings came out as DA: 95%; Ra: 3.163 µm; Rz: 22.99 µm; WL: 0.0182 g; and DR: 0.1277 mm. The validation experiments at the optimized setting showed the close agreement between predicted and experimental values. The morphological study by scanning electron microscopy (SEM) at the optimized setting revealed a significant reduction in surface defects such as micro cracks, micro cavities, globules and sub-surfaces, etc. In a nutshell, the study justified the effectiveness of EDAS-PSO in efficiently predicting the results for machining of pure titanium (Grade 2) using the WEDM process.