Abstract
The present paper identifies the different process parameters that effect the cutting speed and surface roughness in wire electrical discharge machining of Titanium-6-2-4-2 (HSTR aerospace alloy), which is so far not reported in the literature. It also identifies optimal process parameter combination for simultaneous optimization of cutting speed and surface roughness to be presented as a guideline for machining of Titanium-6-2-4-2. Box–Behnken design and response surface methodology are used to plan and analyse the experiments. Six control factors viz. Pulse on time, pulse off time, peak current, spark gap set voltage, wire feed, and wire tension are chosen as process parameters to study the performance of the process in terms of cutting speed and surface roughness. The recommended optimal parameter combinations have been verified by conducting confirmation experiments.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
McGeough, J.A.: Advanced Methods Of Machining. Chapman and Hall, London (1988)
Leigh, E.P.; Schuller, J.K.; Smith, S.: Advanced Machining Techniques on Titanium Rotor Parts. In: 56th annual forum, American Helicopter Society, Virginia Beach, Virginia, USA (2000)
Donachie, M.J.: Titanium: a technical guide, 2nd edn. ASM international, USA (2000)
Yang X.; Liu C.R.: Machining titanium and its alloys. J. Mach. Sci. Technol. 3, 107–139 (1998)
Jeelani, S.: Subsurface plastic deformation in machining 6Al-2Sn-4Zr-2Mo Titanium alloy. Wear 85, 121–130 (1983)
Sarkar, S.; Sekh, M.; Mitra, S.; Bhattacharyya, B.: Modelling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation. J. Mater. Process. Technol. 205, 376–387 (2008)
Rao, R.V.: Advanced Modelling and Optimization of Manufacturing Processes: International Research And Development. Springer, London (2010)
Mahapatra, S.S.; Patnaik, A.:Parametric optimization of wire electrical discharge machining (WEDM) process using Taguchi method. J. Braz. Soc. Mech. Sci. Eng. 28, 422–429 (2006)
ASM Material Data Sheet (Aerospace Specification Metals Inc). http://www.asm.com. 26/12/2008
Kuriakose, S.; Shunmugam, M.S.: Multi-objective optimization of wire-electro-discharge machining process by non-dominated sorting genetic algorithm. J. Mater. Process. Technol. 170, 133–141 (2005)
Liao, Y.S.; Yu, Y.P.: Study of specific discharge energy in WEDM and its application. Int. J. Mach. Tools Manuf. 44, 1373–1380 (2004)
Porous, D.; Zaboruski, S.: Semi empirical model of efficiency of wire electric discharge machining of hard to machine materials. J. Mater. Process. Technol. 209, 1247–1253 (2009)
Saha, P.; Singha, A.; Pal, S.K.: Soft computing models based prediction of cutting speed and surface roughness in wire electro-discharge machining of tungsten carbide cobalt composite. Int. J. Adv. Manuf. Technol. 39, 74–84 (2009)
Liu, J.W.; Yue, T.M.; Guo, Z.N.: Wire electrochemical discharge machining of Al2O3 particle reinforced aluminum alloy 6061. Mater. Manuf. Process. 24, 446–453 (2009)
Khanna, R.; Singh, H.:Parametric optimization of cryogenic treated D-3 for cutting rate in Wire Electrical Discharge Machining. J. Eng. Sci. Technol. 1, 59–64 (2011)
Shah, A.; Mufti, N.A.; Rakwal, D.; Bamberg, E.: Material removal rate, kerf, and surface roughness of tungsten carbide machined with wire electrical discharge machining. Int. J. Mater. Eng. Perform. 20, 71–76 (2010)
Jangra, K.; Jain, A.; Grover, S.: Optimization of multiple-machining characteristics in wire electrical discharge machining of punching die using grey relational analysis. J. Sci. Ind. Res. 69, 606–612 (2010)
Sadeghi, M.; Razavi, H.; Esmaeilzadeh, A.; Kolhan, F.: Optimization of cutting conditions in WEDM process using regression modelling and Tabu search algorithm. Proc I MechE Part B: J. Eng. Manuf. 225, 1825–1834 (2011)
Rao, R.V.; Pawar, P.J.: Modelling and optimization of process parameters of wire electric discharge machining. Procee. IMechE Part B: J. Eng. Manuf. 223, 1431–1440 (2010)
Garg, M.P.; Jain, A.; Bhushan, G.: Investigation of effect of process parameters in wire-EDM of high temperature Titanium alloy 6-2-4-2. In: ICAME 2011: Proceedings of 5th International Conference on advances in Mechanical Engg (NIT Surat, India) 6–8 June, 2011
Myer, R.H.; Montgomery, D.C.: Response Surface Methodology. Wiley, New York (1995)
Myers, R.H.; Montgomery, D.: Response Surface Methodology: Process and Product Optimization Using Designed Experiments, 2nd edn. Wiley, New York (2002)
Guitrau, E.B.: The EDM Handbook. Hanser Gardner Publications, Cincinnati (1997)
Ramakrishnan, R.; Karunamoorthy, L.: Modeling and multi response optimization of Inconel-718 on machining of CNC WEDM process. J. Mater. Process. Technol. 207, 343–349 (2008)
Derringer, G.; Suich, R.:Simultaneous optimization of several response variables. J. Qual. Technol. 12, 214–219 (1980)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Garg, M.P., Jain, A. & Bhushan, G. Multi-objective Optimization of Process Parameters in Wire Electric Discharge Machining of Ti-6-2-4-2 Alloy. Arab J Sci Eng 39, 1465–1476 (2014). https://doi.org/10.1007/s13369-013-0715-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13369-013-0715-x