Optimization of material removal rate and surface characterization of wire electric discharge machined Ti-6Al-4V alloy by response surface method

IF 1.9 Q3 ENGINEERING, MANUFACTURING

Manufacturing Review Pub Date : 2022-01-01 DOI:10.1051/mfreview/2022016

D. Doreswamy, D. Sai Shreyas, Subraya Krishna Bhat, R. Rao

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引用次数: 4

Abstract

Wire electric discharge machining (WEDM) is one of the foremost methods which has been utilized for machining hard-to-cut materials like Titanium alloys. However, there is a need to optimize their important operating parameters to achieve maximum material removal rate (MRR). The present paper investigates the effect of control factors like current, pulse on time (Ton), pulse off time (Toff) on MRR of machining of Ti-6Al-4V alloy. The study showed that, increase in current from 2 A to 6 A results in a significant increase in MRR by 93.27% and increase in Ton from 20 μs to 35 μs improved the MRR by 7.98%, beyond which there was no improvement of MRR. The increase in Toff showed a counterproductive effect. Increase in Toff from 10 μs to 30 μs showed an almost linear decrease in MRR by 52.77%. Morphological study of the machined surface showed that cut surface consists of recast layer on which microcracks were present, and revealed the presence of globules, ridge-structured formations of recast layers and voids. In addition, a regression model was developed to predict the MRR with respect to the control factors, which showed a good prediction with an R2 value of 99.67%.

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响应面法优化电火花加工Ti-6Al-4V合金材料去除率及表面表征

电火花线切割是加工钛合金等难切削材料的主要方法之一。然而，有必要优化其重要的操作参数，以实现最大的材料去除率(MRR)。本文研究了电流、脉冲接通时间(Ton)、脉冲切断时间(Toff)等控制因素对Ti-6Al-4V合金加工MRR的影响。研究表明，当电流从2 A增加到6 A时，MRR显著提高了93.27%;当Ton从20 μs增加到35 μs时，MRR提高了7.98%，超过这一数值后MRR没有提高。托夫的增加显示出适得其反的效果。Toff从10 μs增加到30 μs, MRR几乎呈线性下降，降幅为52.77%。对加工表面的形貌研究表明，切割表面由重铸层组成，重铸层上存在微裂纹，并且存在球状、脊状结构的重铸层和孔洞。此外，建立了相对于控制因素的MRR回归模型，预测效果良好，R2值为99.67%。

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来源期刊

Manufacturing Review ENGINEERING, MANUFACTURING-

CiteScore

5.40

自引率

12.00%

发文量

审稿时长

8 weeks

期刊介绍： The aim of the journal is to stimulate and record an international forum for disseminating knowledge on the advances, developments and applications of manufacturing engineering, technology and applied sciences with a focus on critical reviews of developments in manufacturing and emerging trends in this field. The journal intends to establish a specific focus on reviews of developments of key core topics and on the emerging technologies concerning manufacturing engineering, technology and applied sciences, the aim of which is to provide readers with rapid and easy access to definitive and authoritative knowledge and research-backed opinions on future developments. The scope includes, but is not limited to critical reviews and outstanding original research papers on the advances, developments and applications of: Materials for advanced manufacturing (Metals, Polymers, Glass, Ceramics, Composites, Nano-materials, etc.) and recycling, Material processing methods and technology (Machining, Forming/Shaping, Casting, Powder Metallurgy, Laser technology, Joining, etc.), Additive/rapid manufacturing methods and technology, Tooling and surface-engineering technology (fabrication, coating, heat treatment, etc.), Micro-manufacturing methods and technology, Nano-manufacturing methods and technology, Advanced metrology, instrumentation, quality assurance, testing and inspection, Mechatronics for manufacturing automation, Manufacturing machinery and manufacturing systems, Process chain integration and manufacturing platforms, Sustainable manufacturing and Life-cycle analysis, Industry case studies involving applications of the state-of-the-art manufacturing methods, technology and systems. Content will include invited reviews, original research articles, and invited special topic contributions.