Purpose: In this paper, the effects of various process parameters of WEDM like pulse on time (TON), pulse off time (TOFF), gap voltage (SV), peak current (IP), wire feed (WF) and wire tension (WT) have been investigated to reveal their impact on material removal rate of hot die steel (H-11) using one variable at a time approach. The optimal set of process parameters has also been predicted to maximize the material removal rate. Design/methodology/approach: The experimental studies were performed on ELECTRONICA SPRINTCUT WEDM machine. Findings: The material removal rate (MRR) directly increases with increase in pulse on time (TON) and peak current (IP) while decreases with increase in pulse off time (TOFF) and servo voltage (SV). Practical implications: Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts which have varying hardness, complex shapes and sharp edges that are very difficult to be machined by the traditional machining processes. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted noncontact technique of material removal. Originality/value: We can say that the wire feed and wire tension are neutral input parameters.
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Podstawowym wskaźnikiem w obróbce elektroerozyjnej jest współczynnik względnego zużycia elektrody roboczej n. Współczynnik ten zależy od wielu parametrów, a w szczególności od parametrów wyładowania elektrycznego oraz właściwości materiału elektrod. Przeprowadzone w pracy modelowanie miało na celu wyznaczenie powiązań między wskaźnikami opisującymi usuwanie materiału z elektrod a parametrami obróbki. Do oszacowania objętości usuwanego materiału z elektrod przyjęto model matematyczny erozji elektrycznej dla pojedynczego wyładowania. Oszacowanie usuwania materiału przeprowadzono wykorzystując bilans energetyczny, a także wyznaczany rozkład temperatury w materiale.
EN
Main factor in Electrical Discharge Machining is the relative electrode-tool wear during EDM process. The relative electrode-tool wear depends on many parameters in particular parameter of electrical discharge and properties of electrode materials. The developed mathematical modeling describes relationship between parameters material from electrode and machining parameters. To estimate the volume of material removed from electrode, mathematical model of erosion for single electrical discharge has been applied. Estimation of material removal has been worked out by means of power balance and temperature disposition in the material.
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The present paper deals with temperature distribution into cutting zone during end milling operation of magnesium alloy AZ91HP. The quality of the items is closely related to the state of the surface layer. High temperature generated during cutting process may cause risk of chips ignition when magnesium alloys is subjected to cutting process. Unfavorable phenomena such as the loss of hardness and cutting ability of the cutting tool. In recent years application of thermal imaging technique for monitoring material removal processes has dramatically increased. To determine influence of cutting velocity on maximum temperature appeared during end milling process infrared measurements were conducted. Results and conclusions is presented in the paper.
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