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Optimization of wire electrical discharge turning process: trade-off between production rate and fatigue life

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Abstract

Turning by wire electrical discharge machining (WEDT) has been proven as a successful cutting process for producing complex geometries in difficult-to-cut round bars. However, effects of the process factors on fatigue life and surface integrity have not been studied well. For the first time, in the present investigation it is studied how the WEDT factors influence the surface integrity and subsequent fatigue life of Inconel 718. Experiments were carried out using response surface design taking discharge current, pulse on time, and spindle speed into account as influential parameters. Variation of fatigue life was analyzed and dissuaded by residual stress and surface roughness. Analyses of variance have been taken into account as influential parameters. Finally, a series of optimization results were obtained to understand the trend of fatigue life and material removal rate in Pareto front graphs. Among the obtained results, the one with satisfaction of both responses was compared with the fatigue life and surface integrity of In718 fabricated by the conventional turning process. Results indicated that the fatigue life of parameters at optimum processing conditions (i.e., current of 5 A, pulse time of 1000, and fatigue spindle speed of 250 RPM) can be competitive with finish turning of Inconel 718.

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Funding

This study was financially supported by the Prince Sultan University through the Structures and Materials Research Laboratory.

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Authors and Affiliations

  1. Metamaterials for Mechanical, Biomechanical and Multiphysical Applications Research Group, Ton Duc Thang University, Ho Chi Minh City, Vietnam

    Pouyan Talebizadehsardari

  2. Faculty of Applied Sciences, Ton Duc Thang University, Ho Chi Minh City, Vietnam

    Pouyan Talebizadehsardari

  3. Department of Mechanical and Industrial Engineering, Qatar University, P.O. Box 2713, Doha, Qatar

    Arameh Eyvazian & Farayi Musharavati

  4. Department of Mechanical Engineering, Eastern Mediterranean University, via Mersin 10, Famagusta, North Cyprus, Turkey

    Qasim Zeeshan

  5. Institute of Research and Development, Duy Tan University, Da Nang, 550000, Vietnam

    Roohollah Babaei Mahani

  6. Faculty of Civil Engineering, Duy Tan University, Da Nang, 550000, Vietnam

    Roohollah Babaei Mahani

  7. Engineering Management Department, College of Engineering, Prince Sultan University, Riyadh, Saudi Arabia

    Tamer A. Sebaey

  8. Mechanical Design and Production Department, Faculty of Engineering, Zagazig University, P.O. Box 44519, Sharkia, Zagazig, Egypt

    Tamer A. Sebaey

Authors
  1. Pouyan Talebizadehsardari
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  2. Arameh Eyvazian
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  3. Farayi Musharavati
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  4. Qasim Zeeshan
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  5. Roohollah Babaei Mahani
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  6. Tamer A. Sebaey
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Contributions

Pouya Talebizadeh had 30% contribution in writing the paper and doing research; Arameh Eyvazian had 20% contribution in analyzing the results; Farayi Musharavati had 10% contribution in providing facilities; Qasim Zeeshan had 10% contribution in providing materials and tests; Roohollah Babaei Mahani had 25% contribution while supervising the work; Tamer A. Sebaey had 5% contribution for designing the experimental setup, and facilating the method of investigation as well providing financial aid to perform experiments.

Corresponding author

Correspondence to Roohollah Babaei Mahani.

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Talebizadehsardari, P., Eyvazian, A., Musharavati, F. et al. Optimization of wire electrical discharge turning process: trade-off between production rate and fatigue life. Int J Adv Manuf Technol 112, 719–730 (2021). https://doi.org/10.1007/s00170-020-06351-1

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  • DOI: https://doi.org/10.1007/s00170-020-06351-1

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