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Analysis of the effect of wire electric dischage machining process parameters on the formation of high speed steel form tool

Ishfaq Kashif, Mufti Nadeem Ahmad, Jawad Muhammad, Sajid Muhammad, Jahanzaib Mirza

Advances in Science and Technology. Research Journal

2018

Vol. 12, no 1

89--98

The use of form tools is growing in industry, owing to their inherent advantage of improving productivity. However, the accurate formation of form tool profile is a really tedious task. In this research work, wire electric discharge machining (WEDM) process has been used for the generation of a form tool. Pulse on-time, pulse off-time, servo voltage, wire tension, flushing pressure have been considered as input parameters, whereas tool geometry (clearance angle, included angle), surface roughness and material removal rate are the selected responses. Response surface methodology (RSM) (Box Bhenken experimental design) technique has been used for design of experiments. Analysis of Variance (ANOVA) has shown that pulse on-time and pulse off-time are the two influential control factors for material removal rate (MRR), surface roughness (Ra), clearance angle and included angle. Contour plot analysis has been performed to find out the optimal ranges of the most influential control factors for each response characteristics.

Electrode material on machined surface during spark erosion of Ti-6Al-4V (machined at low range parameters)

Thesiya D., Dave J., Rajurkar A.

Advances in Manufacturing Science and Technology

2014

Vol. 38, nr 4

39--51

Investigation of the machining performance of the titanium alloy (Ti-6Al-4V) at low range parameters by the electrical discharge machining (EDM) using copper and graphite as electrodes with positive polarity. The objective of this paper is to investigate the peak current (A), servo voltage (V), on time (Ton), off time (Toff) and show the effects on material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR). Design of experiments (DOE) method by using Taguchi technique (L18) mixed level implemented. The validity test of the fit and adequacy of the proposed model has been carried out through analysis of variance (ANOVA).SR was set the lower the better to attain the optimum dimensional precision. Experimental results indicate that copper as a tool electrode shows a better surface roughness than a graphite electrode.

W pracy przedstawiono analizę wyników badań obróbki elektroerozyjnej stopu tytanu Ti-6Al-4V w zakresie małej wartości wyładowań elektrycznych z zastosowaniem miedzianej i grafitowej elektrody spolaryzowanej dodatnio. Wyznaczono wpływ parametrów prądowych: natężenia, napięcia, czasu włączenia i wyłączenia na chropowatość powierzchni, prędkość usuwania materiału i zużycie elektrody. W badaniach stosowano zaawansowaną metodę DOE (ang. DOE – Design of Experiments) wyznaczania wpływu zmiennych wejściowych na wynik procesu poddanego analizie. Walidację metody badawczej oraz przyjętego modelu prowadzono z użyciem wariancji ANOVA. Analiza wyników badań potwierdziła, że elektroda miedziana jest lepszym narzędziem do obróbki elektroerozyjnej stopu tytanu.