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1

WEDM parametric study of AA7075/6 wt.% Ni-COATED Al2O3(P) composite miniature GEARS

Praveen D.V., Raju M.V.J., Raju D.R.

Composites Theory and Practice

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2023

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R. 23, nr 2

89--96

EN

Nowadays, gears are essential components in various electro-mechanical devices. Nevertheless, the fabrication of miniature-sized gears is very complicated. The present paper is focused on assessing the influence of the WEDM parameters on the material removal rate (MRR) and surface roughness (Ra) of AA7075/6 wt.% nickel-coated Al2O3 composite miniature gears. Initially, the theoretical design calculations were performed, and consequently the results were validated using ANSYS 19.0 software. Furthermore, experiments were modelled in accordance with Taguchi’s L9 orthogonal array. Optimal combinations of pulse on time, pulse off time and peak current were assessed using grey relational analysis (GRA) coupled with principal component analysis (PCA). The significance of the parametric influence on the machining responses was also evaluated using the ANOVA technique. Consequently, confirmation tests were conducted to verify the optimal parameters and the predicted results are in good agreement with the experimental findings.

2

Effect of different wire materials on WEDM performance of Bio-compatible material

Pandey Gaurav Kumar, Patel Praveen Bhai, Kumar Abhishek, Niranjan Ramendra Singh, Katiyar Vikas, Chandra A. K

Production Engineering Archives

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2022

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Vol. 28, Iss. 1

50--55

EN

The present experimental investigation aims to analyse the effect of various machining parameters, such as pulse peak current (Ion), pulse on time (Ton), pulse off time (Toff) and spark voltage (SV) on the surface roughness (SR) and material removal rate(MRR) by using continuous traveling of both wire electrode (i.e. brass wire and zinc-coated brass wire). The present work also analyses the effect of types of wires, such as brass wire and zinc-coated brass wire used during machining of Titanium alloy (Ti-6Al-4V) on Surface roughness (SR) and material removal rate (MRR). This work studies the correlation between various response parameter such SR and MRR by using same machining parameter by for both wires.

3

Assessing Machinability and Surface Characteristics of a Shape Memory Alloy (SMA) Processed through Wire Electro Spark Erosion Method

Ebenezer George, Khan Adam M., Chellaganesh Duraipandi, Winowlin Jappes J. T., Haider Julfikar

Archives of Metallurgy and Materials

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2022

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Vol. 67, iss. 3

921--930

EN

In this paper, a study was carried out to investigate the surface roughness and material removal rate of low carbon NiTi shape memory alloy (SMA) machined by Wire Electro Spark Erosion (WESE) technique. Experiments are designed considering three parameters viz, spark ON time (SON), spark OFF time (SOFF), and voltage (V) at three levels each. The surface roughness increased from 2.1686 μm to 2.6869 μm with an increase in both SON time, SOFF time and a decrease in voltage. The material removal rate increased from 1.272 mm3/min to 1.616 mm3/min with an increase in SON time but a varying effect was observed the SOFF time and voltage were varied. The analysis revealed that the intensity and duration of the spark had an unswerving relation with the concentration of the microcracks and micropores. More microcracks and micropores were seen in the combination of SON = 120 μs, voltage = 30 V. The concentration of the microcracks and micropores could be minimised by using an appropriate parameter setting. Therefore, considering the surface analysis and material removal, the low carbon NiTi alloy is recommended to machine with 110 μs - 55 μs - 30 V (SON - SOFF - V respectively), to achieve better surface roughness with minimal surface damage.

4

Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

Srivastava Arpit, Verma Mukesh Kumar, Niranjan Ramendra Singh, Chandra Abhishek, Patel Praveen Bhai

Production Engineering Archives

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2021

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Vol. 27, Iss. 4

296--305

EN

Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain significant factors and optimal combinations of process parameters.

5

Multi-objective optimization of the cylindrical grinding process of SCM440 steel using preference selection index method

Tien Dung Hoang, Trung Do Duc, Thien Nguyen Van, Nguyen Nhu-Tung

Journal of Machine Engineering

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2021

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Vol. 21, No. 3

110--123

EN

This paper presents a study to ensure the minimum values of Ra and Rz, and the maximum value of MRR when external cylindrical grinding by the PSI method. The experiments were performed according to the orthogonal Taguchi L9 matrix with the input parameters including workpiece speed, feed rate, and depth of cut in the conventional grinding machine. Analysis of experimental results by Pareto chart showed that the feed rate and the depth of cut most influence on Ra and Rz, respectively. Feed rate and depth of cut all have a great influence on MRR. Meanwhile, the workpiece speed has a negligible effect on all three output parameters. The research results showed that to obtain the minimum values of Ra and Rz, and maximum of MRR, the workpiece speed, feed rate, and depth of cut were 400 rev/min 37.7 mm/min, 0.09 mm/rev, and 0.02 mm, respectively.

6

Experimental investigation of drilling small hole on duplex stainless steel (SS 2205) using EDM

Rajaram S., Rajkumar G., Balasundaram R., Srinivasan D.

Mechanics and Mechanical Engineering

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2019

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Vol. 23, nr 1

98--102

EN

This work investigates drilling of small holes of 3 mm in diameter on duplex stainless steel. Its machinability index is very low (0.66) when compared to other steels; hence, electrical discharge machining is used. The input parameters are current, spark gap, and dielectric pressure. Each input parameter is considered for three levels. Therefore, the total number of experiments is 3 × 3 × 3 = 27. To reduce the number of runs, Taguchi L9 orthogonal array is used, which have the advantage of maximum and minimum trial runs in its design. The output response is metal removal rate (MRR). To find the best operating parameter, the regression model generated using ANOVA is given as input for MATLAB genetic algorithm (GA). The experimental results indicated that models are significant. The test result indicated that the contribution of the current on the MRR is 42.42%, dielectric pressure is 35.36%, and spark gap is 1.93%. From GA, it is observed that among these three factors, lower value of current and dielectric pressure produced the maximum MRR. The SS 2205 has wide variety of applications, such as high pressure components and control valves,which have large number of components attached to it. Hence, performing micro holes on such high hardness alloy is useful.

7

Optimization of machining variables in Electric Discharge Machining using stainless steel 317 in full factorial method

Nandhakumar S., Sathish Kumar S., Sakthivelu K.

Mechanics and Mechanical Engineering

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2018

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Vol. 22, nr 1

105--117

EN

Electric Discharge Machining (EDM) is a non-conventional machining process and has a larger extent of application in manufacturing industry due to its accuracy. EDM simply uses electrical spark between the tool and workpiece in presence of dielectric medium to erode the workpiece in controlled manner. Improving the material removal rate and decreasing the tool wear rate (TWR), achieving higher surface finish, reducing machining time and enhancing dimensional accuracy are the major areas of focus in electrical discharge machining (EDM) process of SS 317 grade steel. In this research work effort to reduce the tool wear rate is concentrated by comparing the machining performance of two distinct electrodes namely copper and brass. Each electrode has their unique machining capabilities and the experimental results were compared in-terms of tool wear rate (TWR), Metal Removal Rate (MRR) and Machining Time (TM). Input variables were optimized based on the experimental output responses to achieve optimal level of input variables.

8

Experimental investigation of drilling small hole on duplex stainless steel (SS2205) using EDM

Rajaram S., Rajkumar G., Balasundaram R., Srinivasan D.

Mechanics and Mechanical Engineering

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2018

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Vol. 22, nr 1

285--293

EN

This work investigates drilling of small holes of Ø 3 mm on duplex Stainless Steel. Its machinability index is very low (0.66) as compared to other steels, hence Electrical Discharge Machine is used. The input parameters are Current, Spark Gap & Di electric Pressure. Each input parameter is considered for 3 levels. Therefore total number of experiments is 3x3x3 – 27. To reduce the number of runs, Taguchi L9 orthogonal array is used, which is having advantage of maximum and minimum trial runs in its design. The output response is metal removal rate. To find the best operating parameter, the regression model of ANOVA is given to input of MAT Lab-Genetic Algorithm. The experimental results indicated that models are significant. The test result indicated that the contributions of current is 42.42%, Di electric pressure is 35.36% and Spark gap is 1.93% on metal removal rate. From Genetic Algorithm it is observed among three levels of factors, lower value of current and Di electric pressure produced maximum metal removal rate. The SS 2205 has wide variety of applications such as high pressure components, control valves etc., which are having large number of components to it. Hence performing micro holes on such high hardness alloy is useful.

9

Design and fabrication of Abrasive Jet Machine (AJM)

Rao P. S. V. R., Naidu A. L., Kona S.

Mechanics and Mechanical Engineering

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2018

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Vol. 22, nr 4

1471--1482

EN

Abrasive Jet Machining (AJM) is the process of material removal from a work piece by the application of a high-speed stream of abrasive particles carried in a gas or air medium from a nozzle. The material removal process is mainly by erosion. The AJM will chiefly be used to cut shapes in hard and brittle materials like glass, ceramics etc. the machine will be automated to have 3 axes travel. The different components of AJM are Compressor, Vibrator, dehumidifier, Pressure Regulator, and Dust filter, Nozzle, Pressure gauge etc. The different components are selected after appropriate design calculations. In paper contains the Abrasive Jet Machine design and fabrication by using available hardware and software etc. taking into consideration of commercially available components. Care has been taken to use less fabricated components rather than directly procuring them, because, the lack of accuracy in fabricated components would lead to a diminished performance of the machine.

10

Optimization of turning process parameters by Taguchi-based Six Sigma

Das P. P., Gupta P., Ghadai R. K., Ramachandran M., Kalita K.

Mechanics and Mechanical Engineering

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2017

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Vol. 21, nr 3

649--656

EN

In this paper, Six Sigma approach is used for improving the quality process outputs in turning of Galvanized Iron. The objective is to optimize the turning parameters and maximize the MRR (Material Removal Rate). A L16 orthogonal array based on Taguchi experiments consisting of three controlling factors viz. spindle speed, feed rate, and depth of cut, each with four levels as required in traditional DOE setting is used here. Taguchi’s parameter design offers an approach in Design of Experiments (DOE) with control parameters optimization to attain best outcome. An orthogonal array offers a set of balanced least experiments which help in data analysis and prediction of optimum results. For each experiment, the Material Removal Rate (MRR) is calculated. The Taguchi method results in reducing the quality characteristic variation due to uncontrollable parameter through the study of response variation using the Signal to Noise (S/N) ratio by the use of Minitab 16 software. Moreover, statistical investigation shows that standard deviation and mean value of confirmation run data are reduced when compare with before Taguchi design run data was performed.

11

Optimization of surface roughness for duplex brass alloy in EDM using response surface methodology

Marichamy S., Saravanan M., Ravichandran M., Stalin B.

Mechanics and Mechanical Engineering

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2017

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Vol. 21, nr 1

57--66

EN

In recent scenario, Duplex brass alloy have drawn many attention of researchers due to the properties such as excellent corrosive resistance, machinability, ductile and easy of fabrication. In present work, the alloy is fabricated by stir casting technique and the machinability was studied during Electric Discharge Machining. In this experiment the control parameters such as current, voltage, pulse on time and flushing pressure were considered to study the effect on Surface roughness (Ra). Response surface methodology (RSM) was used to design the experiment using Box - Behnken design (BBD). An attempt has been made to investigate find out the best optimal parameter for the machining the alloy. The response model has been validated with analysis of variance (ANOVA). Peak current was identified as the significant factor affecting the surface roughness during machining.

12

Experimental investigation and optimization of material removal rate and surface roughness in centerless grinding of magnesium alloy using Grey Relational Analysis

Dinesh S., Mahadevan G., Senthil Kumar T.

Mechanics and Mechanical Engineering

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2017

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Vol. 21, nr 1

17--28

EN

Modern enterprises concentrate on higher production rates with reduced time and admired quality. The surface integrity defines the quality of the product. Several processes like grinding, polishing and buffing have been used to improve the surface texture of the machined products. The most prominent challenge that is faced by an engineer is to manufacture a component with better surface integrity at reduced time, leading to increased production rate and improved profit. It is important to select proper combination of the machining parameters for obtaining the best results. The process called through feed centerless grinding helps in obtaining better surface texture. The main aim of this work is to examine the influence of various machining parameters such as regulating wheel angle, regulating wheel speed and depth of cut over surface roughness and machining time in machining magnesium alloy using silicon carbide grinding wheel. Grey relational analysis method is used for investigating the results. The optimal machining parameters were found with regulating wheel speed, regulating wheel angle and depth of cut being 46 rpm, 2 degree and 0.2 mm.

13

A review on influence of electrical process parameters in EDM process

Muthuramalingam T., Mohan B.

Archives of Civil and Mechanical Engineering

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2015

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Vol. 15, no. 1

87--94

EN

Since the thermal energy produced in electrical discharge machining process is due to the applied electrical energy, it is very important to enhance the electrical process parameters to improve the process efficiency. The present study discusses about having an overview of the EDM process, modeling of process parameters, and influence of process parameters such as input electrical variables, pulse shape, and discharge energy on performance measures such as material removal rate, surface roughness and electrode wear rate. This study also discusses about controlling the electrical process parameters, and empirical relationships between process parameters and optimization of process parameters in EDM process. From the review results, it has been observed that the efficacy of the machining process can be improved by electrical process parameters, and only less attention has been given for enhancing such parameters.

14

Performance analysis of iso current pulse generator on machining characteristics in EDM process

Muthuramalingam T., Mohan B.

Archives of Civil and Mechanical Engineering

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2014

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Vol. 14, no. 3

383--390

EN

Extremely hard materials can be easily machined by Electrical Discharge Machining process due to its thermal erosion nature. In this process, the amount of material removed is directly proportional to the discharge current. Due to the stochastic nature of the thermal erosion process, the discharge current is varied for every applied electrical pulse. It results in different levels of material removal over the material surface during machining process. The volume of the crater is determined by the discharging energy. The variation in the discharging energy produces high surface roughness, which is influenced by discharge current. A constant duration discharge current is needed throughout the process to produce better surface quality. In this research, an iso duration current pulse generator has been proposed to achieve good surface finish. An experimental performance evaluation has been conducted with conventional transistor pulse train generator and modified iso current pulse generator by Taguchi L27 orthogonal array design. The machining characteristics have been evaluated for both the pulse generators. It is found the that modified iso duration current pulse generator has produced better surface quality with higher material removal rate than the conventional transistor pulse train generator.

15

A mathematical model to choose effective cutting parameters in electroerosion, EDM

Medfai A., Boujelbene M., Bayraktar E.

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 47, nr 1

97--102

EN

Purpose: Machining by electroerosion is a process of removal of material by fusion, vaporization and erosion, reserved essentially for conductor and semiconductor materials. It can be used to machine metals and alloys, the tempered steels, different type of ceramic alloys, other metallic carbides and even for harder materials such as polycrystalline diamond etc. The aim of this paper is to develop a mathematical model for the effect of cutting parameters on the machining by electro discharge machining used widely in industrial applications. Design/methodology/approach: It is about a study and detail analyzes effect of the cutting conditions in machining by electroerosion of steel 42CD4-42CrMo4 on the surface quality of the parts. The statistical method of the analysis of variance “ANOVA” makes it possible to release the considerable effects of the parameters of cut on the criteria of performance of machining by electroerosion, EDM. Findings: The result of the study shows that the nature of the electrode used and the different grades of the materials machined by Electro Discharge Machining, EDM, influence considerably the volume of the removal of material and the surface quality of the produced parts. However, more the resistivity of the electrode increases, more relative wear of the electrode will be important and more the volume of removal of material decreases. Research limitations/implications: This study needs more experimental results for evaluation of the cutting parameters in detail and introduce in the model developed here. Practical implications: This model developed based on the experimental study gives very simple choice of cutting parameters depending on the materials. Originality/value: A very simple model has been develop here after a comprehensive study and this model contains an experimental design, and application ANOVA analysis as a function of experimental results and allows to obtain a smooth surface and high quality machined pieces and can decrease at cost price of the pieces in the manufacturing engineering.