Abstract
Wire electric discharge machining (WEDM) is a nontraditional machining technique to cut hard and conductive material with the assistance of a moving electrode. Nanostructured hardfacing material is a hard alloy with high hardness and wear resisting property. The motivation behind this research is to explore the impact of parameters on material removal rate, surface roughness and machining time for WEDM using welded nanostructured hardfacing material as work piece. The hardfacing layer was prepared by manual metal arc welding (MMAW). Taguchi’s L25 orthogonal array was utilized to design the investigational runs. Different hardfaced layer thicknesses were examined to bring out the influence of hardfacing on WEDM performances. Moreover, Multi-objective optimization was carried out using TOPSIS and PCA to recognize optimal process parameters. Optimum combination of input process parameters for the multiple performance characteristics should be preferred as A1B5C5D5E5 (brass wire) and A2B3C4D5E1 (Zinc coated brass wire).
Article PDF
Similar content being viewed by others
Explore related subjects
Discover the latest articles, news and stories from top researchers in related subjects.Avoid common mistakes on your manuscript.
References
Liu D, Liu R, Wei Y, Zhu K (2013) Microstructure and wear properties of Fe-15Cr-2.5 Ti-2C-xB wt% hardfacing alloys. Appl Surf Sci 271:253–259
Io SI, Just C, Xhiku F (2012) Optimisation of multiple quality characteristics of hardfacing using grey-based Taguchi method. Mater Des 33:459–468
Karabasov YS (2002) New materials. Moscow Institute of Steel and Alloys, Moscow
Kuznetsov MA, Zernin EA (2012) Nanotechnologies and nanomaterials in welding production. Welding Int 26:311–313
Majumder H, Maity KP (2018) Predictive analysis on responses in WEDM of titanium grade 6 using General Regression Neural Network (GRNN) and Multiple Regression Analysis (MRA). Silicon. https://doi.org/10.1007/s12633-017-9667-1
Soni H, Narendranath S, Ramesh MR (2018) Effects of wire electro-discharge machining process parameters on the machined surface of Ti50Ni49Co1Shape memory alloy. Silicon. https://doi.org/10.1007/s12633-017-9687-x
Soni H, Narendranath S, Ramesh MR (2018) Experimental investigation on effects of wire electro discharge machining of Ti50Ni45Co5 shape memory alloys. Silicon https://doi.org/10.1007/s12633-018-9780-9
Majumder H, Maity KP (2018) Prediction and optimization of surface roughness and micro-hardness using GRNN and MOORA-fuzzy-a MCDM approach for nitinol in WEDM. Measurement 118:1–13
Majumder H, Maity KP (2017) Optimization of machining condition in WEDM for titanium grade 6 using MOORA coupled with PCA—a multivariate hybrid approach. J Adv Manuf Syst 16:81
Mahapatra SS, Patnaik A (2007) Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method. Int J Adv Manuf Technol 34(9–10):911–925
Bobbili R, Madhu V, Gogia AK (2013) Effect of wire-EDM machining parameters on surface roughness and material removal rate of high strength armor steel. Mater Manuf Process 28(2):364–368
Dhobe MM, Chopde IK, Gogte CL (2014) Optimization of wire electro discharge machining parameters for improving surface finish of cryo-treated tool steel using DOE. Mater Manuf Process 29:1381–1386
Fonda P, Katahira K, Yamazaki K (2012) WEDM condition parameter optimization for PCD microtool geometry fabrication process and quality improvement. Int J Adv Manuf Technol 63:1011–1019
Kumar A, Kumar V, Kumar J (2014) Microstructure analysis and material transformation of pure titanium and tool wear surface after wire electric discharge machining process. Mach Sci Technol 18:47–77
Li L, Li ZY, Wei X T, Cheng X (2015) Machining characteristics of Inconel 718 by sinking-EDM and wire-EDM. Mater Manuf Process 30(8):968–973
Mandal A, Dixit AR, Das AK, Mandal N (2015) Modeling and optimization of machining Nimonic C-263 super alloy using multicut strategy in WEDM. Mater Manuf Process 31(7):860– 868
Manjaiah M, Narendranath S, Basavarajappa S, Gaitonde VN (2015) Effect of electrode material in wire electro discharge machining characteristics of Ti50Ni50−xCuxshape memory alloy. Precis Eng 41:68–77
Shyam L, Sudhir K, Khan ZA, Siddiquee AN (2013) Wire electrical discharge machining of AA7075/SiC/Al2O3 hybrid composite fabricated by inert gas-assisted electromagnetic stir-casting process. J Braz Soc Mech Sci Eng 36(2):335–346
Shayana AV, Afzac RA, Teimourib R (2013) Parametric study along with selection of optimal solutions in dry wirecut machining of cemented tungsten carbide (WC-Co). J Manuf Process 15(4):644–658
Nikalje AM, Kumar A, Sai KVS (2013) Influence of parameters and optimization of EDM performance measures on MDN 300 steel using Taguchi method. Int J Adv Manuf Technol 69:41– 49
Zhang GJ, Zhang Z, Guo JW, Ming WY, Li M Z, Huang Y (2013) Modelling and optimization of medium-speed WEDM process parameters for machining SKD11. Mater Manuf Process 28(10):1124–1132
Bhangoria JL, Puri YM (2010) Kerf width analysis for wire cut electro discharge machining of SS304 L using design of experiments. Ind J Sci Technol 3(4):369–373
Tosun N (2003) The effect of the cutting parameters on performance of WEDM. KSME Int J 17(6):816–824
Tosun N, Cogun C, Tosun G (2004) A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method. J Mater Process Technol 152:316–322
Ahmed LS, Kumar MP (2016) Multiresponse optimization of cryogenic drilling on Ti-6Al-4 V alloy using TOPSIS method. J Mech Sci Technol 30(4):1835–1841
Kalayarasan M, Murali M (2016) Optimization of process parameters in EDM using Taguchi method with grey relational analysis and TOPSIS for ceramic composites. Int J Eng Res Afr 22:83–93
Şimşek B, İç Y T, Şimşek EH (2013) A TOPSIS-based Taguchi optimization to determine optimal mixture proportions of the high strength self-compacting concrete. Chemom Intell Lab Syst 125:18–32
Saha A, Mondal SC (2016) Experimental investigation and modelling of WEDM process for machining nano-structured hardfacing material. J Braz Soc Mech Sci Eng 39:3439–3455
Saha A, Mondal SC (2016) Multi-objective optimization in WEDM process of nanostructured hardfacing materials through hybrid techniques. Measurement 94:46–59
Saha A, Majumder H (2016) Multi criteria selection of optimal machining parameter in turning operation using comprehensive grey complex proportional assessment method for ASTM A36. Int J Eng Res Afr 23:24–32
Fouilland L, Mansori MEI, Gerland M (2007) Role of welding process energy on the microstructural variations in a cobalt base superalloy hardfacing. Surf Coat Technol 201(14):6445–6451
Das CR, Albert SK, Bhaduri AK, Sudha C, Terrance ALE (2005) Characterization of nickel based hardfacing deposits on austenitic stainless steel. Surf Eng 21:29–290
Luo YF (1995) Energy-distribution strategy in fast-cutting wire EDM. J Mater Process Technol 55(3–4):380–390
Shah A, Mufti NA, Rakwal D, Bamberg E (2011) Material removal rate, kerf, and surface roughness of tungsten carbide machined with wire electrical discharge machining. J Mater Eng Perform 20(1):71–76
Kuriakose S, Shunmugam MS (2004) Characteristics of wire-electro discharge machined Ti6Al4 V surface. Mater Lett 58:2231–2237
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Saha, A., Mondal, S.C. Statistical Analysis and Optimization of Process Parameters in Wire Cut Machining of Welded Nanostructured Hardfacing Material. Silicon 11, 1313–1326 (2019). https://doi.org/10.1007/s12633-018-9924-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12633-018-9924-y