REVIEW ON EFFECTS OF PROCESS PARAMETERS IN WIRE CUT EDM

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

REVIEW ON EFFECTS OF PROCESS PARAMETERS IN

WIRE CUT EDM

1M. Tech Student, Department of Mechanical Engineering, Deogiri Institute of Engineering and Management Studies, Aurangabad, Maharashtra, India

2Assistant Professor, Department of Mechanical Engineering, Deogiri Institute of Engineering and Management Studies, Aurangabad, Maharashtra, India

3Assistant Professor & Department of Mechanical Engineering, Deogiri Institute of Engineering and Management Studies, Aurangabad, Maharashtra, India ***

Abstract - WEDM (Wire electrical discharge machining) is a precision machining method for cutting electrically conductive materials. It is an unconventional machining process that produces precision parts that match the dimensional tolerances of our designs within the range of ±0.0001mm. As the residual stress results in premature failure of parts, the WEDM is preferred for hard to machine materials such as Inconel, Nickel, and other Super alloys. In the present paper, earlier and recent work was reviewed, segregated and evaluated on the effect of wire material, diameter, dielectric fluid, wire wear, pulse on and off times and machining characteristics such as kerf size, machining efficiency, material surface characteristics, etc. This paper also focused on hybrid and ultrasonic-assisted WEDM used for machining of different materials. This paper discussed the major research studies in WEDM.

Key Words: WireElectricalDischargeMachine,WireEDM,WPSD2Steel,Pulseontime,PulseoffTime,PeakCurrent,Servo Feed.

1. INTRODUCTION

Machiningprocessplaysamajorroleinmanufacturingindustrieswherequalityandcostaretakenasabenchmark.WEDMis themostinfluentialmachiningprocessesoverallunconventionalmachiningprocessesfordifficulttomachinematerials(such astungstencarbide,graphite,molybdenum,toolsteel,titanium,zirconium,copper,aluminum,Waspaloy,Inconel,Hastelloy, conductiveceramics,polycrystallinediamondcompacts,metalmatrixcompositesetc.)whicharewidelyusedinmanufacturing industriessuchasaerospace,nuclearreactors,automobiles,etc.InWEDM,thematerialremovalprocesswilltakeplacewith thehelpofheatgeneratedbyelectrodesmadeofelectricallyconductivemetals. Themachiningprocesstakesplacewithoutcontactbetweenthewiretoolandtheworkpiece,andthereforethecuttingisdone withoutresidualstress,sincetheworkpiececannotbesubjectedtocuttingpressure.ThistypeofadvantagesmakesWEDMan exemplarymethodformachiningprecisionpartsaswellasmachiningcomplexandhardworkpieceswithcomplicatedprofiles andshapesthataredifficulttomachineonconventionalmachines.WEDMisapotentialthermoelectricmachiningtechnique anditisanon-contactmachiningprocessi.e.,thewireelectrodedoesnotcomeincontactwiththeworkpieceelectrode,this techniquewasinventedforthepurposeofbettermachiningaccuracy.Thematerialwaserodedbyaseriesofcontrolledsparks betweentwoelectrodes.BothelectrodesareconnectedtoaDCpulsepowersourceandimmersedinadielectricliquid;the liquidbehavesasanelectricalconductor,whichbehavesasanelectricalinsulatoruntilthetimeofionization.

Sparkdischargesoccurinthesmallgapbetweentheelectrodeswithafrequencyofthousandsofsparkspersecond.Ateach sparkmomentwithaperiodofapprox.10-4–10-6s,theliquidmediumisdeionizedandionized.Thevicinityofthecutting area isheated to 10,000-20,000ºCandthe dielectric medium aroundthis area evaporates,especiallywhen thepressure increases.Inaddition,asmallamountofworkpiecematerialandwireliquefiesandvaporizes,creatingsmallercratersonthe surfaceoftheworkpiece.Afterthesparkstopsandthestartingmomentbegins,thepressuredropsleadtothecondensationof themetalballsthathavebeendischargedbytheflowingdielectricmedium.

2. LITERATURE REVIEW

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Literature reviews were categorized based on process parameters, electrode wire, material surface, machining efficiency,hybridWEDM,pulse,kerf,dielectricfluid,ultrasonicassistedWEDM,dischargingsystems,dryWEDMand Thermal.Processparameters:Therearefourmajorparameters,whichaffecttheWEDMprocess.Selectionofthe correctparametersforWEDMtogetbetterperformanceisanimportanttask.

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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 08 | Aug 2022 www.irjet.net p-ISSN: 2395-0072

Peak Current: Maximumsuppliedcurrentforeachregularpulsefromthegenerator/powersupply.Gapvoltage:A proper gap is necessary to generate sparks between the workpiece and the wire electrode. Therefore, WEDM dischargegapisabout0.005to1.0mm.

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Servo Feed: Theservofeedsystemprovidesbalancedoperationevenatmachinerunningconditions.(Pofftime>P ontime)

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Pulse on Time: Metalremovalrateiscorrelativetotheamountofpowersuppliedduringthepulseontime.The longerthepulse,themorethematerialwillberemoved.

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Pulse off Time: Onecyclewillfinishwhenrequiredpulseofftimemaintainedpriortostartingofthecomingcycle. Pulseofftimeinfluencesthestabilityandacceleratesthecut.

Table -1: LituratureReview

Sr. No. Author Title

1 DeepakKumar Gupta,Avinash KumarDubey

Multi-processparameter optimizationofwireEDMon shapememoryalloy (Ni54.1Ti)usingTaguchi approach

Tool / Workpiece Material & Specification

1.Workpiece Material-NickelbasedTitanium

2.ToolElectrodeCoCualloy

Processing Parameter

1.PulseonTime (Ton)-18,22,26

2.PulseoffTime (Toff)-40,48,56

3.IpPeakCurrent (A)-160,180,200

Significant Results

1.Pulseontimeisthemost significantparameter,MRRincreases withincreaseTon

2.Optimalparametersforbetter MRRarezinccoatedbrasselectrode Ton26us,Toff48us,andIp200A

3.Theroughnessofthesurface increaseswiththeincreaseofTon 4.Resultsparameterbetterfor surfacefinish

2 M.Arunadevi, C.P.S.Prakash

Predictiveanalysisand multi-objectiveoptimization ofthewire-EDMprocess usingANN

1.Workpiece MaterialAluminumalloy (Al7075)

2.ToolMaterialAlumina(Al2O3)

1.Voltage(Volt)75,100

2.PulseonTime (Ton)-40,30,20

3.PulseoffTime (Toff)-9,12,15

4.Current(I)-2,4, 6

5.BedSpeed(um/s) -50,150,250

Theinfluenceofinputparameters suchaspulse-on,Voltage,pulse-off, current,andbedspeedonMRRand SRisstudiedbymodelingthe experimentaldatausingArtificial NeuralNetwork

4 DivyaMarelli, SateeshN.,and RamSubbiah

Experimentalinvestigation onenhancingdiecorner accuracyduringpowder mixedwireEDMofTi6Al4V

1.Workpiece Material-Ti6Al4V (Titanium-based alloy)

2.ElectrodeEzeecutpluswire electrode

1.Peakcurrent(Ip) -1,2,3,4

2.PulseonTime (Ton)-30,50,70, 90

3.PulseoffTime (Toff)-2,5,8,11

4.PowdertypesB4C,graphite,silica, andAl2O3

Aprominentmethodologynamely Taguchianalysisisappliedto evaluatetheprocessparametersand determinethemostsignificant parameters

Reviewonmulti-objective optimizationofwirecut EDMprocessparameters usinggreyrelationalanalysis

1.Workpiece Material-Inconel 825

2.Electrode-AISI D3

1.PulseonTime (Ton)-

2.PulseoffTime (Toff)-1,3,5

3.Peakcurrent(Ip)

Itisdemonstratedthatthequality characteristicsconsideredinthe presentinvestigationareofboth smallerthe-bettertype(SRandkf) andlargerthe-bettertype(MRR)and

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

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5 OzanCan Ozaner,Gokhan Dursun,Guray Akbulut

Effectsofwire-EDM parametersonthesurface integrityandmechanical characteristicsofadditively manufacturedInconel939

1.Workpiece Material-Inconel 939

2.ElectrodeThermoTex copperwire

6 SahilSharma, UmeshKumar Vates,Amit Bansal

Parametricoptimizationin wireEDMofD2toolsteel usingTaguchimethod

1.Workpiece Material-D2steel (D2toolsteel)

7 RanjitSingh, RaviPratap Singh,Mohit Tyagi,Ravinder Kataria

Investigationofdimensional deviationinwireEDMof M42HSSUsingcryogenically treatedbrasswire

1.Workpiece Material-M42 HSS

8 M.Fakkir Mohammedand K.Lenin

OptimizationofWireEDM processparametersusing Taguchitechnique

1.Workpiece MaterialAluminumAlloy (AA6082-T6)

9 RanuMaurya, RajeshKumar Porwal,Vinod Kumar

Experimentalinvestigation& modelingofwireEDM processduringmachiningof Nicrofer5716

1.Workpiece Material-Nicrofer 5716

10 AshishGoyal, Adithya Garimella, PriyankaSaini

Optimizationofsurface roughnessbythedesignof experimenttechniques duringwireEDMmachining

1.Workpiece Material-Nimonic 80A

-4,8,12

4.Servovoltagesubsequentlyconflictingwithone another

1.PulseonTime (Ton)(us)-0.1,0.4, 0.6

2.PulseoffTime (Toff)(us)-3,6,12 3.Voltage(V)-80, 120,200

1.ThesurfacepropertiesofInconel 939areconsiderablyaffected byWireEDMparametersasthemain inputssuchaspulseon,pulseoffand voltageleadstonoteworthychange

2.InadditiontoexaminingtheWire EDMparametersindividually,itwas foundthatsurfaceintegrityis affectedbytheratiowithpulseoff andpulseon

1.PulseonTime (Ton)-113,116, 119

2.PulseoffTime (Toff)-30,35,40

3.Peakcurrent(Ip) -170,200,230

4.Wiretension-8, 10,12

1.PulseonTime (Ton)-110,115, 120(mu)

2.PulseoffTime (Toff)-45,50,55 (mu)

3.SparkGapVoltage (SV)-40,50,60(V)

4.WireFeed(WF)3,5,7(m/min)

1.PulseonTime (Ton)(us)-33,36, 39

2.PulseoffTime (Toff)(us)-5,7,10

3.Current(A)-1, 1.5,2

1.PulseonTime (Ton)(us)-8,10, 12

2.PulseoffTime (Toff)(us)-57,60, 63

3.Servofeed(Sv)7,10,13

1.Peakcurrent(A)6,7,8

2.PulseonTime(B) -0.7,0.9,1.1

3.PulseoffTime(C) -4,5,6

4.Feedrate(D)-5, 7,9

1.UsingTaguchitechniqueforTon initiallydecreasesandfurther increases

2.ValueofMRRforToffconstantly reduces

3.ThevalueofMRRforIpincreases byincreasinglevel

1.Thepulseontime(Ton)andpulse offtime(Toff)havemorediscernible impactsonthedimensionaldeviation oftheprocessedM42workmaterial

InTaguchiAnalysisSurface RoughnessversusPulseon,Pulseoff andCurrenthascarriedoutan averageofeverylevelintermsofS/N ratiosarea

Thefactorpulseontimehasagreat impactonboththeperformance characteristicsascomparedtothe othertwomachiningfactors.Ithas beenobservedthatasTnincreases Mrincreaseswhilethereis subsequentdegradationinsurface qualityandviceversa.

TheTaguchi’smethodhasbeen employedinevaluatingtheinfluence ofsurfaceroughnessduetofour inputparametersasprocess parameters

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 08 | Aug 2022 www.irjet.net p-ISSN: 2395-0072

11 UmangMaradia, EricFilisetti, MoritzWiessner, Sebastian Schneider, Marco Boccadoro

TheInfluenceofenergy inputcharacteristicsof surfaceintegrityinwire EDM

1.Workpiece MaterialTungstenCarbide WC-CO(RGM30)

1.Peakcurrent(Ip) -216,210,300,242

2.PulseDuration (te)-0.85,1.53, 1.41,1.75

3.PulseEnergy(E)2.34,4.09,5.39

4.PulseFrequency (f)-90,51,10,26.7

Acomprehensiveanalysisof dischargeenergycharacteristicsin wireEDMoftoolsteelandtungsten carbideidentifiestheappliedpower asthemostsignificantfactorfor productivityandpulsedurationfor surfaceintegrity

12 AyushOwhal, Nandam SrinivasaRao, Umashankar Gupta,Murlidhar Mahajana

ExtensionofWire-EDM CapabilityforTurning TitaniumAlloyandan ExperimentalStudyfor ProcessOptimizationby GreyRelationalAnalysis

13 Nancharaiah Tata,RaviKumar Pacharu,Sameer Kumar Devarakonda

Multiresponseoptimization ofprocessparametersin wire-cutEDMonINCONEL 625

1.Workpiece MaterialTitaniumAlloy

1.PulseonTime (Ton)(us)-8,9,10

2.PulseoffTime (Toff)(us)-50,50, 50

3.Workfeed(Sv)6,10,14(m/s)

Themaineffectsonindividual performanceparameter,whereMRR increaseswithTonasenergy dischargerateincreases,but decreaseswithRPMandWF

1.Workpiece Material-Inconel 625

2.Tool-Brass wireelectrode

1.PulseonTime (Ton)-125,130, 135(sec)

2.PulseoffTime (Toff)-30,35,40 (sec)

3.Supplyvoltage (V)-15,20,25 (volts)

Theeffectsoftheinputparameter, i.e.,Dischargecurrent,Pulseontime andvoltageonMRR,surface roughness(SR)ofInconel625 machinedworkpiecewerecalculated withbrassWiretoolusingTaguchi method

14 B.SelvaBabu,S. Sathiyaraj, Anantha KrishnanP. Ramesh,B.A. Afridi,K.Kristo Varghese

15 MalayaKumar Debta,Ravi Mishra,Manoj Mahanta

Investigationofmachining characteristicsofaluminum 6061bywirecutEDM process

1.Workpiece MaterialAluminum6061

2.Tool-Brass wireelectrode

Experimentalinvestigation onthemachining performanceofAZ91D(90% Mg)alloybywire-cutEDM

1.PulseonTime (Ton)(us)-32,34, 36

2.PulseoffTime (Toff)(us)-6,7,8

3.Peakcurrent(Ip) -1,2,3

Theeffectofprocessparameterson theprocessperformanceby performingdifferentexperiments. WEDMofAI6061indicatepeak currentandPulseonhavinga significanteffectonMRRandSR

1.Workpiece Material-AZ91D (90%Mg)Alloy

1.PulseonTime (Ton)(us)-100, 105,110

2.WireFeed-5 m/mi

3.Peakcurrent(Ip) -110A

4.Servovoltage-22 V

5.Pulsefrequency2100Hz

Atconstantwiretensionwith increasedTonthecuttingvelocity increasesgradually

16 P.Sivaprakasam, P.Hariharan,S. Gowri

Experimentalinvestigations onnanopowdermixed Micro-WireEDMprocessof Inconel-718alloy

1.Workpiece Material-Inconel 718Alloy

1.Voltage(V)-80, 90,100

2.Capacitance(uF)0.0001,0.01,0.1

3.Concentration (g/kg)-0,0.25,0.5

Machiningparameterssuchas voltage(A),capacitance(B),powder concentration(C),theinteractionof voltage&capacitance(AB),and capacitance&powderconcentration (BC)haveasignificantinfluenceon materialremovalrateofpowder mixedMicro-WireEDMprocess

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 08 | Aug 2022 www.irjet.net p-ISSN: 2395-0072

17 K.Hareesh,K.V. NalinaPramod, N.K.LinuHusain, K.B.Binoy,R. DipinKumar, N.K.Sreejith

18 P.M.Abhilash andD. Chakradhar

Influenceofprocess parametersofwireEDMon thesurfacefinishofTi6Al4V

1.Workpiece Material-Ti6Al4V ofTitaniumAlloy

Failuredetectionandcontrol forwireEDMprocessusing multiplesensors

1.Workpiece Material-Inconel 718

2.Electrode-Zinc coatedelectrode

1.Voltage-HV,LV

2.WireSpeed-2,3, 2,3

3.FeedRate-30, 60,90,120,150 (Hz)

1.PulseonTime (Ton)(us)-105, 110,115

2.PulseoffTime (Toff)(us)-30,40, 50

3.InputcurrentIp (A)-40,10

Theprocessparametersuchaswire speed,voltage,andfeedrateare optimizedforwireelectricdischarge machiningofTi6Al4V

Machiningfailureisdefinedwhen eitherofthefollowingcasesoccurs: (a)whentheprocessfailstoperform therequiredfunction,or (b)whenabreakdowneventcauses aninterruption

AnExperimentalStudyon roundnesserrorinwire EDMforFeromaterials

1.Workpiece Material-Ferro materials

1.Tension(N)-6

2.WireFeed (m/min)-12

3.FlushingPressure (kg/cm2)-4

4.Current(A)-100

1.Thethicknessofworkpiece dimensionsoftheblunder,Spout separationaffectingcuttingrate

2.Theresultwasfoundavarietyof blundersdimensionally0.004

3. CONCLUSIONS

Fromthestudy,itwasfoundthatalltheinputparameterssignificantlyaffecttheWireEDMprocess.Amongthesignificant factors,pulseontime,pulseofftime,andpeakcurrenthavethemaximuminfluenceonthewholeprocess.Wirefeed,wire tension,andwaterpressurehaveminimaleffectsontheprocess.Therefore,itisnecessarytooptimizetheprocessparameters toachievethedesiredresults.

HerearesomepointsthatshouldalwaysbekeptinmindwhiledoingresearchworkonWEDMprocessparameters:

1. Thehigherthecurrentvalue,thegreatertheintensityofthespark,andtheresultisahighrateofmaterialremoval.

2. Surfaceroughnesscanbeimprovedbyreducingpulsedurationanddischargecurrent.

3. Increasingpulsedurationandopen-circuitvoltageincreasethewirewearratio,whileincreasingwirespeeddecreases it.

4. Thenewlydevelopedhigh-speedwirescangreatlyincreasetheproductionspeedcomparedtothecommonlyused brasswireandgalvanizedsurfacewire.

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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 08 | Aug 2022 www.irjet.net p-ISSN: 2395-0072

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