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Multi-Response Optimization of Rotary Electrode EDM Process Parameters for Tungsten Carbide

Sabry Ibrahim, Mourad Abdel Hamid I., ElWakil Mohamed, Hewidy Ahmed M.

Management and Production Engineering Review

2025

Vol. 16, No. 1

1--13

Electrical discharge machining (EDM) is a potent technique widely applied to machining materials like EN-8M steel and composite materials. The surface quality achieved through EDM is significantly affected by the settings of its parameters and the type of material being processed. In this context, the focus of research has often been on heavy metals and titanium and magnesium alloys among lighter metals. This study aims to investigate the impact of EDM parameters, specifically on Tungsten Carbide, a material gaining traction across various industries. Our research involved a thorough parametric analysis utilizing a full factorial method to examine factors influencing surface roughness (SR) and material removal rate (MRR). This paper highlights the optimization of MRR using a Rotary electrode attachment. Experiments were conducted employing factorial design to delve deeper into the machining characteristics of Tungsten Carbide with a 4 mm Brass-coated rod as the electrode. Key parameters such as summit current, electrode rotation speed, and Pulse on time were systematically adjusted. The analysis of the machining parameters revealed their significant influence on the outcomes, with p-values falling below 0.05, underscoring their critical role in the EDM process. The developed mathematical models demonstrated a high R-squared value alongside minimal error percentages. The most critical parameters identified for optimal results included an electrode rotational speed of 150 rpm, a summit current of 1.22 A, and a Pulse on time set at 8.45 ms.

Multi-weld Quality Optimization of Friction Stir Welding for Aluminium Flange Using the Grey-based Taguchi Method

Sabry Ibrahim, ElWakil Mohamed, Hewidy A. M.

Management and Production Engineering Review

2024

Vol. 15, No. 2

42--56

Friction stir welding (FSW) is gaining traction as a preferred technique due to its potential to reduce heat input and enhance the mechanical properties of welded joints. However, the path to commercializing FSW for flange joints is not without challenges. Two primary obstacles are the complexity of the welding path and the intricate design requirements for the fixtures. These factors contribute to the difficulty in determining the ideal weld settings and process parameters, which are critical for achieving optimal results. The current study addresses these challenges by applying FSW to flange joints using custom-engineered fixtures. These fixtures are meticulously designed to hold the pipes and plates securely during the welding process. The focus of the research is on optimizing the multi-performance characteristics of FSW for Al 6063 flange joints through the hybrid Grey-based Taguchi method. The integrity of the weld joint is assessed by examining various mechanical properties within the weld zone, including rotation speed, travel speed, tool profile, and shoulder diameter. The study identifies the optimal parameter settings for the FSW process: a rotation speed of 3000 rpm, a travel speed of 3 mm/min2, a shoulder diameter of 20 mm, and a conical tool profile. Under these ideal conditions, the welded material exhibited a tensile strength of 170.169 MPa, a hardness of 63.7709 HV, and a corrosion rate of 0.022 mm/year. These findings underscore the effectiveness of the optimized FSW process in producing robust and durable flange joints.