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Effects of multi-pass cutting during wire electrical discharging

  • Gurusamy Selvakumar , Velayutham Balasubramanian , Sundaravel Vijayan and Nagarajan Lenin
Published/Copyright: August 30, 2019
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Materials Testing
From the journal Materials Testing Volume 61 Issue 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

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

© 2019, Carl Hanser Verlag, München

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  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

Articles in the same Issue

  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
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