Wire Rupture Optimization in Wire Electrical Discharge Machining using Taguchi Approach

Wire electrical discharge machining (WEDM) is one of the most important nontraditional machining process that is well-known for cutting difficult to machine materials. The wire electrode along with machining parameters control the WEDM process. This research work focuses on optimizing WEDM parameters using Taguchi technique to minimize wire rupture. Experiments have been done using the L18 orthogonal array. Each experiment is repeated three times to ensure accurate readings of the wire rupture. The statistical methods of signal to noise ratio (S/N ratio) is applied to study effects of peak current, pulse width, charging time, wire speed, and wire tension on wire rupture. As a results, the peak current, pulse width, and wire tension have the most significant effect on wire rupture followed by charging time and wire speed. The developed analysis can be used in the metal cutting field to identify the optimum machining parameters for less wire rupture

Analytical modeling of grinding wheel loading phenomena

Wheel surface condition plays an important role in the grinding operation. Grinding wheel loading, meaning chip accumulation in the space between grains, leads to deteriorating wheel cutting ability and causes excessive force and temperature. This paper presents an analytical model of wheel loading phenomena as a function of cutting parameters, wheel structure, and material properties. The model is based on the adhesion of workpiece material to abrasive grain surface. It is validated by experimental results from grinding nickel-based superalloy with cubic boron nitride vitrified wheel. This model considers wheel specifications including abrasive grains size and the number of cutting edges. Cutting parameters and process temperature are the other determinant factors. On the basis of this model and empirical results, the effects of the various process parameters are presented

Wire Rupture Optimization in Wire Electrical Discharge Machining using Taguchi Approach

Wire electrical discharge machining (WEDM) is one of the most important nontraditional machining process that is well-known for cutting difficult to machine materials. The wire electrode along with machining parameters control the WEDM process. This research work focuses on optimizing WEDM parameters using Taguchi technique to minimize wire rupture. Experiments have been done using the L18 orthogonal array. Each experiment is repeated three times to ensure accurate readings of the wire rupture. The statistical methods of signal to noise ratio (S/N ratio) is applied to study effects of peak current, pulse width, charging time, wire speed, and wire tension on wire rupture. As a results, the peak current, pulse width, and wire tension have the most significant effect on wire rupture followed by charging time and wire speed. The developed analysis can be used in the metal cutting field to identify the optimum machining parameters for less wire rupture

Plasma thermal spray of ceramic oxide coating on carbon steel with enhanced wear and corrosion resistance for oil and gas applications

In this work, carbon steel surface was coated with Al2O3–40 wt% TiO2 composite using thermal spraying method. The tribological properties of the plasma-sprayed Al2O3–40 wt% TiO2 coating were investigated with a tribometer (pin-on-disc) to evaluate and compare the wear properties of coated and uncoated samples under different loads. Additionally, cumulative weight analysis was done to compare wear loss. The results indicate significant anti-wear improvement with an increase in TiO2 from 13 wt% to 40 wt%. The corrosion on coated and uncoated samples was analyzed using AC and DC methods, namely open circuit potential from potentio-dynamic polarization and electrochemical impedance spectroscopy in 3% NaCl solution for 20 days

Enhanced surface roughness of AISI D2 steel machined using nano-powder mixed electrical discharge machining

Manufacturing geometrically complex components with high strength and high wear resistance is an essential requirement in fabricating heavy-duty industrial components. Electrical Discharge Machining (EDM) is a non-conventional machining technique with the potential to machine any conductive material regardless of hardness property. This experiment concentrates on Powder Mixed EDM (PMEDM), where a specific concentration of titanium powder is added to the dielectric. The effect of adding powder is investigated on machined surface roughness. It is revealed that for 120 µsec and 210 µsec spark durations, the impact of titanium particles significantly improves the Ra and Rz of the AISI D2 steel machined surface. However, increasing the spark duration to 340 µsec leads to surface roughness deterioration owing to debris particles adhering onto the surface

Investigation into effect of silicon morphology on surface roughness while machining Al-Si-Cu-Mg alloy

Surface roughness is one of the key measures in manufacturing that describes machined surface integrity. In this research work, the effect of silicon morphology on surface roughness when turning Al-11%Si-1.8%Cu alloy and Sr-containing alloys was investigated. The experiments are carried out under oblique dry cutting conditions using a PVD TIN-coated insert at three cutting speeds of 70, 130 and 250 m/min, feed rates of 0.05, 0.1, 0.15 mm/rev, and 0.05 mm constant depth of cut. The result released that surface roughness decreased with adding 0.04 wt.% Sr to casting. The surface roughness values reduce with cutting speed increment from 70 m/min to 250 m/min. Also, the surface finish deteriorated with increase in feed rate from 0.5 mm/rev to 0.15 mm/rev

Characterization of biogenic hydroxyapatite derived from animal bones for biomedical applications

© 2018 Elsevier Ltd and Techna Group S.r.l. In this work, the viability of producing biogenic hydroxyapatite from bio-waste animal bones, namely bovine (cow), caprine (goat) and galline (chicken), through a heat treatment process has been investigated. The animal bones were locally sourced, cleaned to remove collagen and subsequently heat treated in air atmosphere at different temperatures ranging from 600 °C to 1000 °C. From the range of sintering temperatures investigated, it was found that hydroxyapatite derived from bovine bone showed good thermal stability while those produced from caprine and galline bones exhibited phase instability with traces of tri-calcium phosphate (TCP) being detected after heat treatment beyond 700 °C. The porous nature of the bone samples can be observed from the microstructures obtained and supported by low relative density. Heating the bovine and caprine bones at selected temperatures yielded porous HA body, having hardness values that are comparable with human cortical bone. However, the sintered galline bone sample showed higher porosity levels and low hardness when compared to the other two bone types