Startseite Effects of multi-pass cutting during wire electrical discharging
Artikel
Lizenziert
Nicht lizenziert Erfordert eine Authentifizierung

Effects of multi-pass cutting during wire electrical discharging

  • Gurusamy Selvakumar , Velayutham Balasubramanian , Sundaravel Vijayan und Nagarajan Lenin
Veröffentlicht/Copyright: 30. August 2019
Veröffentlichen auch Sie bei De Gruyter Brill
Manuskript einreichen Informationen für Autor*innen
Materials Testing
Aus der Zeitschrift Materials Testing Band 61 Heft 9

Abstract

In recent years, the use of wire electrical discharge machining (WEDM) has gained momentum for processing hardened alloys. The machining of a hardened alloy commonly reveals poor surface finish and poor corner accuracy. In order to improve the machining performance, multi-pass cutting was employed during wire EDM of Monel 400 alloy. In this work, multi- pass cutting is achieved by one rough cut followed by two trim cuts. Control factors such as offset distance, pulse-on time (Ton), corner angle, flushing nozzle height, pulse-off time (Toff), open circuit voltage and wire tension are selected as control factors in so far as the process criteria results in reduced speed, corner error and surface roughness. The experiments were carried out using Taguchi design, and the results were analyzed. These showed that surface finish and corner accuracy were improved if the machining had been performed with a single trim cut. The outcome of the results revealed that the use of a trim cut more than once adversely affects the productivity and accuracy of the products in question. Moreover, a comparative study on (i) a single pass cut versus a trim cut (ii) a trim cut versus path modification was carried out.

∗Correspondence Address, Dr. G. Selvakumar, Department of Mechanical Engineering, SSN College of Engineering, Chennai, 603 110, India, E-mail: ,

Dr. Gurusamy Selvakumar, born in 1978, received his PhD in Engineering from Jadavpur University, Kolkata, India in 2013. He has 16 years of professional experience in teaching and research. Currently, he is working as Associate Professor in the Mechanical Engineering Department at the Sri Sivasubramaniya Nadar (SSN) College of Engineering, Chennai, India. He has published 26 international journal papers, two national journal papers, 19 conference papers, three edited books and a reference book in the area of advanced manufacturing processes. One research project sponsored by SERB is in progress.

Velayutham Balasubramanian, born in 1979, received his M. E. (Manufacturing Engg.) from Anna University, Chennai, India in 2005. He works as an Assistant Professor in the Mechanical Engineering Department at the Sardar Raja College of Engineering, Alangulam, India. He is pursuing a Ph.D. in the area of wire EDM at the Sri Sivasubramaniya Nadar (SSN) College of Engineering, Chennai, India, under the supervision of Dr G Selvakumar. He has had 14 years of teaching experience.

Dr. Sundaravel Vijayan, is an Associate Professor in the Department of Mechanical Engineering at SSN College of Engineering, Chennai, and has 20 years of teaching experience. He received his Bachelor of Engineering (B. E.) in Mechanical Engineering from Madurai Kamarajar University in 1997, completed his post-graduate Masters of Engineering (M. E.) in Industrial Engineering at the Thigarajar College of Engineering in 1998 and a Ph.D. from Anna University in the year 2010. He has completed two research sponsored projects funded by the Naval Research Board, DRDO and SSN Trust. He has published 20 International journals papers to his credit. He advises PhD candidates and has published two books for VDM-Verlag and Lambert, respectively. He has assumed administrative responsibilities such as Chairman Valuation at Anna University and Controller of Examination at SSN.

Dr. Nagarajan Lenin is presently an Associate Professor in the Department of Mechanical Engineering at Veltech Dr.RR and Dr.SR University, Chennai, Tamil Nadu, India and has been teaching for 12 Years. He wrote his Ph.D thesis the simultaneous minimization of objectives in single row facility layout problems'. His other areas of research interest include machining & welding process parameters, optimization and machinability, & tribological studies on composite materials. He has published in reputable international journals and participated in international and national conferences which have also published his research work.

References

1 K. H.Ho, S. T.Newman, S.Rahimifard, R. D.Allen: State of the art in wire electrical discharge machining, International Journal of Machine Tools and Manufacture44 (2004), pp. 1247–125910.1016/j.ijmachtools.2004.04.017Suche in Google Scholar

2 S.Sarkar, M.Sekh, S.Mitra, B.Bhattacharyya: A novel method of determination of wire lag for enhanced profile accuracy in WEDM, Precision Engineering35 (2011), pp. 339–34710.1016/j.precisioneng.2011.01.001Suche in Google Scholar

3 J. T.Huang, Y. S.Liao, W. J.Hsue: Determination of finish-cutting operation number and machining parameters setting in wire electrical discharge machining, Journal of Materials Processing Technology87 (1999), pp. 69–8110.1016/S0924-0136(98)00334-3Suche in Google Scholar

4 M.Kunieda, C.Furudate: High precision finish cutting by Dry WEDM, Annals of the CIRP50 (2001), pp. 121–12410.1016/S0007-8506(07)62085-XSuche in Google Scholar

5 A. B.Puri, B.Bhattacharyya: An analysis and optimization of the geometrical inaccuracy due to wire lag phenomenon in WEDM, International Journal of Machine Tools and Manufacture43 (2003), pp. 151–15910.1016/S0890-6955(02)00158-XSuche in Google Scholar

6 S.Kuriakose, M. S.Sunmugam: Multi-objective optimization of WEDM process by Non-Dominated sorting generic algorithm, Journal of Materials Processing Technology170 (2005), pp. 133–14110.1016/j.jmatprotec.2005.04.105Suche in Google Scholar

7 S.Sarkar, M.Sekh, S.Mitra, B.Bhattacharyya: Modelling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation, Journal of Materials Processing Technology205 (2008), pp. 376–38710.1016/j.jmatprotec.2007.11.194Suche in Google Scholar

8 J. A.Sanchez, J. L.Rodil, A.Herrero: On the influence of cutting speed limitation on the accuracy of wire EDM corner cutting, Journal of Materials Processing Technology182 (2007), pp. 574–57910.1016/j.jmatprotec.2006.09.030Suche in Google Scholar

9 F.Han, J.Jiang, D.Yu: Influence of machining parameters on surface roughness in finish cut of WEDM, The International Journal of Advanced Manufacturing Technology34 (2007), pp. 538–54610.1007/s00170-006-0629-9Suche in Google Scholar

10 M. Q.Li, M.Li, G. Y.Xiong: Study on the variations of form and position of the wire electrode in WEDM-HS, The International Journal of Advanced Manufacturing Technology25 (2005), pp. 929–93410.1007/s00170-003-1915-4Suche in Google Scholar

11 J. A.Sanchez, L. N. Lopezde Lacalle, A.Lamikiz: A computer- aided system for the optimization of the accuracy of the wire electro-discharge machining process, International Journal of Computer Integrated Manufacturing17 (5) (2004), pp. 413–42010.1080/09511920310001626590Suche in Google Scholar

12 S.Sarkar, K.Gosh, S.Mitra, B.Bhattacharyya: An Integrated approach to optimization of WEDM combining single-pass and multi-pass cutting operation, Materials and Manufacturing Processes25 (2010), pp. 799–80710.1080/10426910903575848Suche in Google Scholar

13 G.Selvakumar, S.Sarkar, S.Mitra: Experimental investigation on die corner accuracy for wire electrical discharge machining of Monel 400 alloy, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture226 (2012), pp. 694–170410.1177/0954405412456660Suche in Google Scholar

14 G.Selvakumar, K. B.Jiju, S.Sarkar, S.Mitra: Enhancing die corner accuracy through trim cut in WEDM, The International Journal of Advanced Manufacturing Technology83 (2016), pp. 791–80310.1007/s00170-015-7606-0Suche in Google Scholar

15 G.Selvakumar, K. G. ThiruppatKuttalingam, M.Selvaraj, J.Manohar: Enhancing die corner accuracy using path modification strategy in WEDM of Monel 400 alloy, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science232 (2018), No. 2, pp. 207–21610.1177/0954406216679436Suche in Google Scholar

16 T.Muthuramalingam, B.Mohan: A review on influence of electrical process parameters in EDM process, Archives of Civil and Mechanical Engineering15 (2015), pp. 87–9410.1016/j.acme.2014.02.009Suche in Google Scholar

Published Online: 2019-08-30
Published in Print: 2019-08-30

© 2019, Carl Hanser Verlag, München

Artikel in diesem Heft

  1. Inhalt/Contents
  2. Contents
  3. Fachbeiträge/Technical Contributions
  4. In situ computed tomography for the characterization of the fatigue damage development in glass fiber-reinforced polyurethane
  5. Phase evolution of surface-modified Incoloy 825 superalloy using pack aluminization
  6. Material qualification of a 13Cr-L80 casing for sour conditions
  7. Influence of processing parameters on the fatigue life time of specimens made from quenched and tempered steel SAE 4140H
  8. Impact of notch geometry on dynamic strength of materials
  9. Hygrothermal environment effects on mechanical properties of T700/3228 CFRP laminates
  10. Effect of austenitizing temperature on the microstructure evolution and properties of Cu-bearing CADI
  11. Characterization of the boron layer formed by pack boronizing of binary iron-niobium alloys
  12. Corrosion inhibition of steel in a sodium chloride solution by natural honey
  13. Effect of notch-depth ratio on intermittent electromagnetic radiation from Cu-Ni alloy under tension
  14. Physical, mechanical and thermal behavior of recycled agro waste GSA reinforced green composites
  15. Effects of multi-pass cutting during wire electrical discharging
  16. Effects of thrust force variation during the drilling of pure and chemically treated Kevlar based polymer composites
  17. Dynamic mechanical and fracture morphology of kevlar fiber filled groundnut reinforced epoxy composites
https://doi.org/10.3139/120.111400

Artikel in diesem Heft

  1. Inhalt/Contents
  2. Contents
  3. Fachbeiträge/Technical Contributions
  4. In situ computed tomography for the characterization of the fatigue damage development in glass fiber-reinforced polyurethane
  5. Phase evolution of surface-modified Incoloy 825 superalloy using pack aluminization
  6. Material qualification of a 13Cr-L80 casing for sour conditions
  7. Influence of processing parameters on the fatigue life time of specimens made from quenched and tempered steel SAE 4140H
  8. Impact of notch geometry on dynamic strength of materials
  9. Hygrothermal environment effects on mechanical properties of T700/3228 CFRP laminates
  10. Effect of austenitizing temperature on the microstructure evolution and properties of Cu-bearing CADI
  11. Characterization of the boron layer formed by pack boronizing of binary iron-niobium alloys
  12. Corrosion inhibition of steel in a sodium chloride solution by natural honey
  13. Effect of notch-depth ratio on intermittent electromagnetic radiation from Cu-Ni alloy under tension
  14. Physical, mechanical and thermal behavior of recycled agro waste GSA reinforced green composites
  15. Effects of multi-pass cutting during wire electrical discharging
  16. Effects of thrust force variation during the drilling of pure and chemically treated Kevlar based polymer composites
  17. Dynamic mechanical and fracture morphology of kevlar fiber filled groundnut reinforced epoxy composites
Jetzt anmelden und 20% sparen
Institutioneller Zugang
Wie funktioniert Authentifizierung?
Haben Sie eine Idee, wie wir unsere Website verbessern können?
Bitte schreiben Sie uns.
© 2025 De Gruyter Brill
Heruntergeladen am 11.11.2025 von https://www.degruyterbrill.com/document/doi/10.3139/120.111400/html
Button zum nach oben scrollen