Effect of cutting parameters on surface roughness and wire consumption during wire electro-discharge machining
The wire electro-discharge machining technique is used in many operations, from the simplest cutting applications to the manufacturing of complex and delicate parts. Costs and the variety of wire used in the cutting process vary according to the particular workpiece to be cut. The literature on this...
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| Published in | Materialprüfung Vol. 59; no. 3; pp. 278 - 283 |
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| Main Authors | , , |
| Format | Journal Article |
| Language | English |
| Published |
De Gruyter
02.03.2017
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| Online Access | Get full text |
| ISSN | 0025-5300 2195-8572 |
| DOI | 10.3139/120.110998 |
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| Abstract | The wire electro-discharge machining technique is used in many operations, from the simplest cutting applications to the manufacturing of complex and delicate parts. Costs and the variety of wire used in the cutting process vary according to the particular workpiece to be cut. The literature on this subject features studies conducted on the surface roughness and the metal removal rate. However, the surface sensitivity in the manufacturing of cutting dies is not a crucial property. The most important variable, rather, is the cost involved in making simple cutting dies. In this study, a Böhler K100 workpiece and CuZn37 wire material has been used to find the optimal conditions for high quality surface roughness, maximizing metal removal rate and minimizing wire consumption. Furthermore, the metal removal rate related directly to the cutting speed was calculated and compared with the consumption. To facilitate calculation of wire consumption, the evolutionary programming module was used for modeling and derivation of the formula for calculation with 99 % accuracy. |
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| AbstractList | The wire electro-discharge machining technique is used in many operations, from the simplest cutting applications to the manufacturing of complex and delicate parts. Costs and the variety of wire used in the cutting process vary according to the particular workpiece to be cut. The literature on this subject features studies conducted on the surface roughness and the metal removal rate. However, the surface sensitivity in the manufacturing of cutting dies is not a crucial property. The most important variable, rather, is the cost involved in making simple cutting dies. In this study, a Böhler K100 workpiece and CuZn37 wire material has been used to find the optimal conditions for high quality surface roughness, maximizing metal removal rate and minimizing wire consumption. Furthermore, the metal removal rate related directly to the cutting speed was calculated and compared with the consumption. To facilitate calculation of wire consumption, the evolutionary programming module was used for modeling and derivation of the formula for calculation with 99 % accuracy. |
| Author | Sofu, Mehmet Mahir Kayacan, Mehmet Cengiz Hamamcı, Emre |
| Author_xml | – sequence: 1 givenname: Mehmet Mahir surname: Sofu fullname: Sofu, Mehmet Mahir organization: 1 Isparta – sequence: 2 givenname: Emre surname: Hamamcı fullname: Hamamcı, Emre organization: 2 Kars – sequence: 3 givenname: Mehmet Cengiz surname: Kayacan fullname: Kayacan, Mehmet Cengiz organization: 3 Isparta, Turkey |
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| References_xml | – volume: 2 start-page: 1021 issue: 5 year: 2010 end-page: 1028 ident: j_120.110998_ref_002 article-title: Statistical and regression analysis of material removal rate for wire cut electro discharge machining of SS 304L using design of experiments publication-title: International Journal of Engineering Science and Technology – volume: 1 start-page: 51 issue: 2 year: 2013 end-page: 56 ident: j_120.110998_ref_010 article-title: Parametric effect on wire breakage frequency and surface topography in WEDM of pure titanium publication-title: Journal of Mechanical Engineering and Technology doi: 10.18005/JMET0102003 – volume: 170 start-page: 133 issue: 1–2 year: 2005 end-page: 141 ident: j_120.110998_ref_008 article-title: Multi-objective optimization of wire-electro discharge machining process by non-dominated sorting genetic algorithm publication-title: Journal of Materials Processing Technology doi: 10.1016/j.jmatprotec.2005.04.105 – volume: 76 start-page: 91 issue: 1–4 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| Title | Effect of cutting parameters on surface roughness and wire consumption during wire electro-discharge machining |
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