Skip to main content
Log in

Semi-empirical model on MRR and overcut in WEDM process of pure titanium using multi-objective desirability approach

  • Technical Paper
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Titanium and its alloys have been experiencing extensive development over the past few decades stimulated by a series of their unique properties, i.e. high strength to weight ratio maintained at elevated temperature, high hot hardness, high fracture resistance, and exceptional resistance to corrosion at temperature below 500 °C. Machining of titanium, however, is considered as cumbersome with the conventional manufacturing practices, and there is a critical need for developing and establishing cost-effective methods of machining. This research work is mainly focused on the effect of WEDM parameters, such as pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate and wire tension has been varied to investigate their effect on material removal rate and overcut for pure titanium. The experiments are planned, conducted, and analyzed through response surface methodology. An attempt has also been made to construct a micro-model for prediction of material removal rate using dimensional analysis. The predictions from this model have been validated by conducting experiments.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26

Similar content being viewed by others

References

  1. Hong SY, Markus I, Jeong W (2001) New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4 V. Int J Mach Tools Manuf 41:2245–2260

    Article  Google Scholar 

  2. Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68:262–274

    Article  Google Scholar 

  3. Wood RA, Favor RJ (1972) Titanium alloys handbook. Air Force Materials Laboratory, Ohio, 45433, pp 45-46

  4. Sommer C, Sommer S (2005) Complete EDM handbook. Advance Publishing Inc, Houston

  5. Lin YC, Yan BH, Chang YS (2000) Machining characteristics of titanium alloy (Ti-6Al-4V) using a combination process of EDM with USM. J Mater Process Technol 104:171–177

    Article  Google Scholar 

  6. Islam MN, Rafai NH, Subramanian SS (2010) An investigation into dimensional accuracy achievable in wire-cut electrical discharge machining. In: Proceedings of the World Congress on Engineering, vol III, London, UK

  7. Miller SF, Shih AJ, Qu J (2004) Investigation of the spark cycle on material removal rate in wire electrical discharge machining of advanced materials. Int. J Mach Tool Manuf 44:391–400

  8. Liao YS, Huang JT, Su HC (1997) A study on the machining parameters optimization of the wire electrical discharge machining. J Mater Process Technol 71(3):487–493

    Article  Google Scholar 

  9. Huang JT, Liao YS (2003) Optimization of machining parameters of wire-EDM based on grey relational and statistical analysis. Int J Prod Res 41(8):1707–1720

    Article  MATH  Google Scholar 

  10. Rajurkar KP, Wang WM (1993) Thermal modeling and on-line monitoring of wire EDM. J Mater Process Technol 38(1–2):417–430

    Article  Google Scholar 

  11. Hewidy MS, El-Taweel TA, El-Safty MF (2005) Modeling the machining parameters of wire electrical discharge machining of Inconel 601 using RSM. J Mater Process Technol 169:328–336

    Article  Google Scholar 

  12. Mahapatra SS, Patnaik A (2007) Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method. Int J Adv Mfg Technol 34(9–10):911–925

    Article  Google Scholar 

  13. Ramakrishnan R, Karunamoorthy L (2006) Multi response optimization of wire EDM operations using robust design of experiments. Int J Adv Manuf Technol 29:105–112

    Article  Google Scholar 

  14. Manna A, Bhattacharya B (2006) Taguchi and gauss elimination method: a dual response approach for parametric optimization of CNC wire cut EDM of PRAISiCMMC. Int J Adv Manuf Technol 28:67–75

    Article  Google Scholar 

  15. Kozak J, Rajurkar KP, Chandarana N (2004) Machining of low electrical conductivity material by wire electric discharge machining. J Mater Process Technol 149:266–271

    Article  Google Scholar 

  16. Rao PS, R, Koona R, Satyanarayana B (2010) Prediction of material removal rate for Aluminum BIS-24345 alloy in wire-cut EDM. Int J Eng Sci Technol 2(12):7729–7739

  17. Sarkar S, Mitra S, Bhattacharyya B (2006) Parametric optimization of wire electrical discharge machining of γ titanium aluminide alloy through an artificial neural network model. Int J Adv Manuf Technol 27:501–508

    Article  Google Scholar 

  18. Singh H, Khanna R (2011) Parametric optimization of cryogenic-treated D-3 for cutting rate in wire electrical discharge machining. J Eng Technol 1:59–64

    Article  Google Scholar 

  19. Yang Tai, Rong Tzeng, Jyh Chorny, Yang Kuang, Yung Hsieh, Hua Ming (2012) Optimization of wire electric discharge machining parameters for cutting tungsten. Int J Adv Manuf Technol 60(1–4):135–147

    Article  MATH  Google Scholar 

  20. Kumar A, Kumar V, Kumar J (2011) Effect of machining parameters on MRR during CNC WEDM of pure titanium. In: Proceedings of the 5th international conference on advances in mechanical engineering, S.V. National Institute of Technology, Surat, India, 6–8 June, pp 541–545

  21. Kumar A, Kumar V, Kumar J (2012) An investigation into machining characteristics of commercially pure Titanium (Grade-2) using CNC WEDM. Appl Mech Mater 159:56–68

    Article  Google Scholar 

  22. Kumar A, Kumar V, Kumar J (2012) Prediction of surface roughness in wire electric discharge machining (WEDM) process based on response surface methodology. Int J Eng Technol 2(4):708–719

    Google Scholar 

  23. Kumar A, Kumar V, Kumar J (2013) Multi-response optimization of process parameters based on response surface methodology for pure titanium using WEDM process. Int J Adv Manuf Technol 68(9–11):2645–2668

    Article  Google Scholar 

  24. Kumar A, Kumar V, Kumar J (2013) Investigation of machining parameters and surface integrity in wire electric discharge machining of pure titanium. Proc I Mech Eng Part B J Eng Manuf 227(7):972–992

  25. Kumar A, Kumar V, Kumar J (2013) Surface integrity and material transfer investigation of pure titanium for rough cut surface after wire electro discharge machining. Proc I Mech Eng Part B J Eng Manuf, 0954405413513013

  26. Kumar Anish, Kumar Vinod, Kumar Jatinder (2013) Experimental Investigation on material transfer mechanism in WEDM of pure titanium (Grade-2). Adv Mater Sci Eng 2013:1–20

    Article  MATH  Google Scholar 

  27. Kumar Anish, Kumar Vinod, Kumar Jatinder (2013) Microstructure analysis and material transformation of pure titanium and tool wear surface after wire electric discharge machining. Mach Sci Technol 18(1):47–77

    Article  Google Scholar 

  28. Kumar Anish, Kumar Vinod, Kumar Jatinder (2013) Investigation of microstructure and element migration for rough cut surface of pure titanium after WEDM. Int J Micro Mater Prop 8(4):343–356

    Google Scholar 

  29. Kumar Anish, Kumar Vinod, Kumar Jatinder (2013) Metallographic analysis of pure titanium (grade-2) surface by wire electro discharge machining process (WEDM). J Mach Manuf Autom 2(1):1–5

    Google Scholar 

  30. Kumar Anish, Kumar Vinod, Kumar Jatinder (2013) Parametric effect on wire breakage frequency and surface topography in WEDM of pure titanium. J Mech Eng Technol 1(2):51–56

    Google Scholar 

  31. Kumar A, Kumar V, Kumar J (2013) Effect of machining parameters on dimensional deviation in wire electric discharge machining process using pure titanium. J Eng Technol 3(2):105–112

    Article  Google Scholar 

  32. Kumar Anish, Kumar Vinod, Kumar Jatinder (2011) A review on the state of the art in wire electric discharge machining (WEDM). Int J Mech Eng Res Deve 1(1):23–39

    Google Scholar 

  33. Kumar A, Kumar V, Kumar J (2012) A state of art in development of wire electrodes for high performance wire cut EDM. In: International conference on advancements and futuristic trends in mechanical and materials engineering. Punjab technical University, Jalandhar, 5–7 October, pp 70–78

  34. Kumar A, Kumar V, Kumar J (2011) A review on effect of WEDM performance recast layer and wire accuracy. In: First national conference on advances in mechanical engineering, UIET, Punjab University, Chandigarh, May, 20–21, pp 408–414

  35. Shah A, Mufti NA, Rakwal D, Bamberg E (2010) Material removal rate, kerf, and surface roughness of tungsten carbide machined with wire electrical discharge machining. Int J Mater Eng Perform 20(1):71–76

    Article  Google Scholar 

  36. Sadeghi M, Razavi H, Esmaeilzadeh A, Kolahan F (2011) Optimization of cutting conditions in WEDM process using regression modelling and Tabu search algorithm. Proc I Mech Eng Part B J Eng Manuf 225(10):1825–1834

  37. Porous D, Zaboruski S (2009) Semi empirical model of efficiency of wire electric discharge machining of hard to machine materials. J Mater Process Technol 209(3):1247–1253

    Article  Google Scholar 

  38. Liu JW, Yue TM, Guo ZN (2009) Wire electrochemical discharge machining of Al2O3 particle reinforced aluminum alloy 6061. Mater Manuf Process 24(4):446–453

    Article  Google Scholar 

  39. Somashekhar KP, Ramachandran N, Jose Mathew (2011) Material removal characteristics of microslot (kerf) geometry in µ-WEDM on aluminum. Int J Adv Manuf Technol 51:611–626

    Article  Google Scholar 

  40. Tzeng CJ, Yang YK, Hsieh MH, Jeng MC (2011) Optimization of wire electrical discharge machining of pure tungsten using neural network and response surface methodology. Proc I Mech Eng Part B J Eng Manuf 225:841–852

    Google Scholar 

  41. Rao PV, Pawar PJ (2009) Modeling and optimization of process parameters of wire electrical discharge machining. Proc. I. Mech Eng Part B J Eng Manuf 223:1431–1440

    Article  Google Scholar 

  42. Patil GN, Brahmankar PK (2010) Determination of metal removal rate in wire electro-discharge machining of metal matrix composites using dimensional analysis. Int J Adv Mfg Technol 51:599–610

  43. Langhaar HL (1951) Dimensional analysis and theory of models. Wiley, New York

    MATH  Google Scholar 

  44. Derringer G, Suich R (1980) Simultaneous optimization of several response variables. J Qual Technol 12:214–219

    Google Scholar 

  45. Castillo ED, Montgomery DC, McCarville DR (1996) Modified desirability functions for multiple response optimizations. J Qual Technol 28(3):337–345

    Google Scholar 

Download references

Acknowledgments

The authors acknowledge to General Manager, Central tool room (CTR), Ludhiana, Punjab, India, for providing the necessary wire electric discharge machine set-up and other facilities during the research work.

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Anish Kumar.

Additional information

Technical Editor: Alexandre Mendes Abrao.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kumar, A., Kumar, V. & Kumar, J. Semi-empirical model on MRR and overcut in WEDM process of pure titanium using multi-objective desirability approach. J Braz. Soc. Mech. Sci. Eng. 37, 689–721 (2015). https://doi.org/10.1007/s40430-014-0208-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40430-014-0208-1

Keywords

Navigation