Ti-6Al-4V is a lightweight,extremely strong material with high resistance to corrosion and is widely used in aerospace industries,medical implants and many more.Contour cutting in such material with sharp corner radiu...Ti-6Al-4V is a lightweight,extremely strong material with high resistance to corrosion and is widely used in aerospace industries,medical implants and many more.Contour cutting in such material with sharp corner radius,narrow kerf width,and maintaining high dimensional accuracy and surface integrity is a challenge for the modern manufacturing industry.Wire Electrical Discharge Machining(WEDM) is a feasible process to meet the above challenges.However,proper control of process parameters is highly necessary for quality cutting of such material.In order to meet the above challenges,the present work focuses on the optimum selection of different process parameters such as pulse-on time(T_(ON)),pulse-off time(T_(OFF)),spark gap voltage(SV) and wire feed rate(WF) using Taguchi-based Multi Response Signal to Noise ratio(MRSN) technique.This is a very simple multi response optimization technique to simultaneously optimize vital responses like thickness of white layer formed on the machined surfaces,average crack density,surface roughness and dimensional accuracy,without the assistance of any software.Moreover,simple regression models are developed to determine the above responses for any combination of process parameters.Industry personnel will find this study useful in utilizing this expensive non-conventional machining method in a techno-economic manner.展开更多
Wire⁃Electrical Discharge Machining(WEDM)process can create any complex contour in any conducting material,regardless of its strength or hardness,with higher accuracy.Present experimental investigation aims to determi...Wire⁃Electrical Discharge Machining(WEDM)process can create any complex contour in any conducting material,regardless of its strength or hardness,with higher accuracy.Present experimental investigation aims to determine suitable input process/machining parameters,e.g.pulse on time(TON),peak current(IP),wire feed rate(WF),and pulse off time(TOFF),for optimizing the process performances,namely,cutting rate,kerf width,average roughness value of the machined surface,micro hardness,and surface crack density.Since four input parameters are considered in the present investigation,and each parameter is assumed to vary at three different levels(i.e.low,medium,high),the Taguchi L9 Orthogonal Array(OA)design approach has been used for the experimental purpose to enhance the process effiency.Similarly,a simple and popular multiresponse optimization approach,namely Grey Relational Analysis(GRA),is used to optimize five performance characteristics(output responses)simultaneously.The optimum process variables obtained are:TON of 110μs,TOFF of 40μs,IP of 10 A,and WF of 6 mm/min.These optimum process variables are validated with confirmatory experiment.The relative impact of input variables is determined using the Analysis of Variance(ANOVA)technique.Finally,correlations between individual outputs with different input parameters are established.This work will be helpful for industry personnel to use this machining process in a techno⁃economic way.展开更多
文摘Ti-6Al-4V is a lightweight,extremely strong material with high resistance to corrosion and is widely used in aerospace industries,medical implants and many more.Contour cutting in such material with sharp corner radius,narrow kerf width,and maintaining high dimensional accuracy and surface integrity is a challenge for the modern manufacturing industry.Wire Electrical Discharge Machining(WEDM) is a feasible process to meet the above challenges.However,proper control of process parameters is highly necessary for quality cutting of such material.In order to meet the above challenges,the present work focuses on the optimum selection of different process parameters such as pulse-on time(T_(ON)),pulse-off time(T_(OFF)),spark gap voltage(SV) and wire feed rate(WF) using Taguchi-based Multi Response Signal to Noise ratio(MRSN) technique.This is a very simple multi response optimization technique to simultaneously optimize vital responses like thickness of white layer formed on the machined surfaces,average crack density,surface roughness and dimensional accuracy,without the assistance of any software.Moreover,simple regression models are developed to determine the above responses for any combination of process parameters.Industry personnel will find this study useful in utilizing this expensive non-conventional machining method in a techno-economic manner.
文摘Wire⁃Electrical Discharge Machining(WEDM)process can create any complex contour in any conducting material,regardless of its strength or hardness,with higher accuracy.Present experimental investigation aims to determine suitable input process/machining parameters,e.g.pulse on time(TON),peak current(IP),wire feed rate(WF),and pulse off time(TOFF),for optimizing the process performances,namely,cutting rate,kerf width,average roughness value of the machined surface,micro hardness,and surface crack density.Since four input parameters are considered in the present investigation,and each parameter is assumed to vary at three different levels(i.e.low,medium,high),the Taguchi L9 Orthogonal Array(OA)design approach has been used for the experimental purpose to enhance the process effiency.Similarly,a simple and popular multiresponse optimization approach,namely Grey Relational Analysis(GRA),is used to optimize five performance characteristics(output responses)simultaneously.The optimum process variables obtained are:TON of 110μs,TOFF of 40μs,IP of 10 A,and WF of 6 mm/min.These optimum process variables are validated with confirmatory experiment.The relative impact of input variables is determined using the Analysis of Variance(ANOVA)technique.Finally,correlations between individual outputs with different input parameters are established.This work will be helpful for industry personnel to use this machining process in a techno⁃economic way.
