Abstract
Wire electric discharge machining (WEDM) is a specialized, electrothermal, nontraditional process to machine complex shapes. The aim of this research is to optimize the WEDM operating attributes with the objective of achieving a maximum material removal rate (MRR) and minimum roughness of the machined surface (Ra) for a stellite (6B grade) alloy. Taguchi experimentation (L27) was carried out to determine the influence of machining attributes on the output responses. The influence of process attributes was studied using an analysis of variance (ANOVA) concatenated with grey relational analysis and the fuzzy logic concept. Scanning electron microscopy was performed to characterize the recast layer on the machined surface. Based on multiple objective criteria for achieving the maximum MRR and minimum Ra, the optimal coalition of process attributes was 80 μs pulse-on time, 10 μs pulse-off time, 3 m/min wire feed rate, 5 A peak current and 40 μm/s bed speed.
Similar content being viewed by others
References
A. Pramanik and G. Littlefair, Machining of Titanium Alloy (Ti-6Al-4V)-Theory to Application, Mach. Sci. Technol., 2015, 19(1), p 1–49.
K. Singh, K. Goyal, and D.K. Goyal, Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel, Adv. Eng. Forum., 2018, 28, p 55–66.
T. Thankachan, K. Soorya Prakash, and M. Loganathan, WEDM Process Parameter Optimization of FSPed Copper-BN Composites, Mater. Manuf. Process., 2018, 33(3), p 350–358.
K.S. Prakash, T. Thankachan, and R. Radhakrishnan, Parametric Optimization of Dry Sliding Wear Loss of Copper–MWCNT Composites, Trans. Nonferrous Met. Soc. China, 2017, 27(3), p 627–637.
H. Singh, K. Goyal, and P. Kumar, Experimental Investigation of WEDM Variables on Surface Roughness of AISI H13, Manuf. Sci. Technol., 2013, 1(2), p 23–30.
K. Mandal, S. Sarkar, S. Mitra, and D. Bose, Parametric Analysis and GRA Approach in WEDM of Al 7075 Alloy, Mater. Today Proc., 2020, 26, p 660–664.
A.S. Shivade and V.D. Shinde, Multi-objective Optimization in WEDM of D3 Tool Steel using Integrated Approach of Taguchi Method & Grey Relational Analysis, J. Ind. Eng. Int., 2014, 10(4), p 149–162.
R. Chaudhari, J. Vora, D.M. Parikh, V. Wankhede, and S. Khanna, Multi-response Optimization of WEDM Parameters using an Integrated Approach of RSM–GRA Analysis for Pure Titanium, J. Inst. Eng. India D, 2020, 101, p 117–126.
T. Thankachan, K.S. Prakash, R. Malini, S. Ramu, P. Sundararaj, S. Rajandran, D. Rammasamy, and S. Jothi, Prediction of Surface Roughness and Material Removal Rate in Wire Electrical Discharge Machining on Aluminum Based Alloys/Composites using Taguchi Coupled Grey Relational Analysis and Artificial Neural Networks, Appl. Surf. Sci., 2019, 472, p 22–35.
S. Ozturk, Machinability of Stellite-6 Coatings with Ceramic Inserts and Tungsten Carbide Tools, Arab. J. Sci. Eng., 2014, 39, p 7375–7383.
Y. Jia, B.S. Kim, D.J. Hu, and J. Ni, Experimental Investigations into Near-Dry Milling EDM of Stellite Alloys, Int. J. Mach. Mach. Mater., 2010, 7(1–2), p 96–111.
L. Urtekin, H.B. Ozerkan, C. Cogun, A. Genc, Z. Esen, and F. Bozkurt, Experimental Investigation on Wire Electric Discharge Machining of Biodegradable AZ91 Mg Alloy, J. Mater. Eng. Perf., 2021, 30(10), p 7752–7761.
R.S. Gill, K. Kumar, and U. Batra, Surface Characteristics and Corrosion Behaviour of Wire Electrical Discharge Machining Processed Mg-4Zn Alloy, J. Mater. Eng. Perf., 2021, 30, p 2955–2966.
N. Kuruvila and H.V. Ravindra, Parametric Influence and Optimization of Wire EDM of Hot Die Steel, Mach. Sci. Technol., 2011, 15(1), p 47–75.
N. Tosun, C. Cogun, and A. Inan, The Effect of Cutting Parameters on Workpiece Surface Roughness in Wire EDM, Mach. Sci. Technol., 2003, 7(2), p 209–219.
A. Ramamurthy, R. Sivaramakrishnan, T. Muthuramalingam, and S. Venugopal, Performance Analysis of Wire Electrodes on Machining Ti-6Al-4V Alloy using Electrical Discharge Machining Process, Mach. Sci. Technol., 2015, 19(4), p 577–592.
S. Tripathy and D.K. Tripathy, Multi-response Optimization of Machining Process Parameters for Powder Mixed Electro-Discharge Machining of H-11 Die Steel using Grey Relational Analysis and Topsis, Mach. Sci. Technol., 2017, 21(3), p 362–384.
R. Raju, N. Manikandan, D. Palanisamy, D. Arulkirubakaran, S. Sambathkumar, and P.B. Prakash, Optimization of Process Parameters in Electrical Discharge Machining of Haste Alloy C276 using Taguchi’s Method, Mater. Today Proc., 2018, 5(6), p 14432–14439.
V. Balaji and S. Narendranath, Influence of Wire-Electric Discharge Machining Process Parameters on Surface Integrity of Ni-rich Ni-Ti-Hf alloys, Eng. Res. Express, 2023, 5, p 025065.
A. Pramanik, A.K. Basak, M.N. Islam, and G. Littlefair, Electrical Discharge Machining of 6061 Aluminium Alloy, Trans. Nonferrous Met. Soc. China, 2015, 25(9), p 2866–2874.
S.K. Kar, P.K. Mishra, A.K. Sahu, S.S. Mahapatra, and J. Thomas, Multi-objective Optimization of Wire-EDM of Inconel 625 by using Desirability Function Approach, Int. J. Interact. Des. Manuf., 2023, 17(2), p 931–938.
I.V. Manoj, H. Soni, S. Narendranath, P.M. Mashinini, and F. Kara, Examination of Machining Parameters and Prediction of Cutting Velocity and Surface Roughness using RSM and ANN using WEDM of Altemp HX, Adv. Mater. Sci. Eng., 2022, 2022, p 1–9.
B.P. Singh, J. Singh, J. Singh, and D. Goyal, Experimental Investigation of Machining Nimonic-80A Alloy on Wire EDM using Response Surface Methodology, Met. Powder Rep., 2021, 76, p S9–S17.
R. Bobbili, V. Madhu, and A.K. Gogia, Effect of Wire-EDM Machining Parameters on Surface Roughness and Material Removal Rate of High Strength Armor Steel, Mater. Manuf. Process., 2013, 28(4), p 364–368.
M.M. Kane, A.A. Phanse, H.J. Bahirat, and S.V. Kulkarni, Classification and Comparative Study of EDM Pulse Generators, IET. Power Electron., 2020, 13(14), p 2943–2959.
A. Goswami and J. Kumar, Trim Cut Machining and Surface Integrity Analysis of Nimonic 80A Alloy using Wire Cut EDM, Eng. Sci. Tech. Int. J., 2017, 20(1), p 175–186.
D.A.N. Scott, S. Boyina, and K.P. Rajurkar, Analysis and Optimization of Parameter Combinations in Wire Electrical Discharge Machining, Int. J. Prod. Res., 1991, 29(11), p 2189–2207.
C. Balasubramaniyan, K. Rajkumar, and S. Santosh, Wire-EDM Machinability Investigation on Quaternary Ni44Ti50Cu4Zr2 Shape Memory Alloy, Mater. Manuf. Process., 2021, 36(10), p 1161–1170.
D. Deepak, M.C. Gowrishankar, and D.S. Shreyas, Investigation on the Wire Electric Discharge Machining Performance of Artificially Aged Al6061/B4C Composites by Response Surface Method, Mater. Res., 2022, 25, p 20220010.
S. Singh and A. Bhardwaj, Review to EDM by using Water and Powder-Mixed Dielectric Fluid, J. Miner. Mater. Char. Eng., 2011, 10(02), p 199.
M. Manjaiah, R.F. Laubscher, A. Kumar, and S. Basavarajappa, Parametric Optimization of MRR and Surface Roughness in Wire Electro Discharge Machining (WEDM) of D2 Steel using Taguchi-Based Utility Approach, Mech. Mater. Eng. Int. J, 2016, 11(1), p 1–9.
M. Ansari and I.A. Khan, Investigation on the Performance of Wire Electrical Discharge Machining (WEDM) using Aluminium Matrix Composites (AMCs) Micro-Channel, Eng. Res. Express., 2023, 5(3), p 035065.
M. Manjaiah, S. Narendranath, and S. Basavarajappa, Wire Electro Discharge Machining Performance of TiNiCu Shape Memory Alloy, SILICON, 2016, 8, p 467–475.
V.R. Dalve, R. Keshavamurthy, G. Ugrasen, and C.P.S. Prakash, Experimental Investigations on Wire EDM of Al7075-TiB2 In Situ Metal Matrix Composite, Appl. Mech. Mater., 2014, 592, p 321–325.
V. Kavimani, K.S. Prakash, and T. Thankachan, Influence of Machining Parameters on Wire Electrical Discharge Machining Performance of Reduced Graphene Oxide/Magnesium Composite and its Surface Integrity Characteristics, Compos. B Eng., 2019, 167, p 621–630.
D. Devarasiddappa and M. Chandrasekaran, Experimental Investigation and Optimization of Sustainable Performance Measures during Wire-Cut EDM of Ti-6Al-4V Alloy Employing Preference-Based TLBO Algorithm, Mater. Manuf. Process., 2020, 35(11), p 1204–1213.
A. Mandal, A.R. Dixit, A.K. Das, and N. Mandal, Modeling and Optimization of Machining Nimonic C-263 Superalloy using Multicut Strategy in WEDM, Mater. Manuf. Process., 2016, 31(7), p 860–868.
N. Naeim, M.A. AbouEleaz, and A. Elkaseer, Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304, Materials, 2023, 16(3), p 1–16.
M. Manjaiah, S. Narendranath, S. Basavarajappa, and V.N. Gaitonde, Influence of Process Parameters on Material Removal Rate and Surface Roughness in WED-Machining of Ti50Ni40Cu10 Shape Memory Alloy, Int. J. Mach. Mach. Mater., 2016, 18(1–2), p 36–53.
F. Nourbakhsh, K.P. Rajurkar, A.P. Malshe, and J. Cao, Wire Electro-Discharge Machining of Titanium Alloy, Procedia Cirp., 2013, 5, p 13–18.
V.K. Pasam, S.B. Battula, P. Madar Valli, and M. Swapna, Optimizing Surface Finish in WEDM using the Taguchi Parameter Design Method, J. Braz. Soc. Mech. Sci., 2010, 32, p 107–113.
M.U. Iqbal, J. Santhakumar, and S. Dixit, Multi-objective Optimization of WEDM Process Parameters on Titanium Grade 9 using ANN and Grey Relational Analysis, AIP Conf. Proc., 2022, 2460(1), p 030008.
S.A. El-Bahloul, Optimization of Wire Electrical Discharge Machining using Statistical Methods Coupled with Artificial Intelligence Techniques and Soft Computing, SN Appl. Sci., 2020, 2, p 1–8.
A. Goyal, H.U. Rahman, and S.A.C. Ghani, Experimental Investigation & Optimisation of Wire Electrical Discharge Machining Process Parameters for Ni49Ti51 Shape Memory Alloy, J. King Saud Univ. Eng. Sci., 2021, 33(2), p 129–135.
S.S. Nain, D. Garg, and S. Kumar, Performance Evaluation of the WEDM Process of Aeronautics Super Alloy, Mater. Manuf. Process., 2018, 33(16), p 1793–1808.
I.V. Manoj and S. Narendranath, Wire Electric Discharge Machining at Different Slant Angles during Slant Type Taper Profiling of Microfer 4722 Superalloy, J. Mater. Eng. Perform., 2022, 31(1), p 697–708.
Y. Wang, D. He, L. Yang, and W. Xiong, Formation Mechanism of Surface Topography in Low-Speed Wire Electrical Discharge Machining Inconel 718 and its On-Line Prediction Based on Acoustic Emission Technology, Adv. Mech. Eng., 2017, 9(4), p 1–17.
K. Mouralova, J. Kovar, L. Klakurkova, J. Bednar, L. Benes, and R. Zahradnicek, Analysis of Surface Morphology and Topography of Pure Aluminium Machined using WEDM, Measurement, 2018, 114, p 169–176.
Y.H. Guu, AFM Surface Imaging of AISI D2 Tool Steel Machined by the EDM Process, Appl. Surf. Sci., 2005, 242(3–4), p 245–250.
D. Kumar, K.K.S. Mer, H.S. Payal, and K. Kumar, White-Layer Thickness on Edm-Processed AISI A2 Steel–Mathematical Modeling and Analysis, Mater. Technol., 2022, 56(2), p 97–106.
B.E. Kmekci, Residual Stresses and White Layer in Electric Discharge Machining (EDM), Appl. Surf. Sci., 2007, 253(23), p 9234–9240.
T.R. Newton, S.N. Melkote, T.R. Watkins, R.M. Trejo, and L. Reister, Investigation of the Effect of Process Parameters on the Formation and Characteristics of Recast Layer in Wire-EDM of Inconel 718, Mater. Sci. Eng. A, 2009, 513, p 208–215.
G. Ebenezer, M. Adam Khan, D. Chellaganesh, and J. Haider, Assessing Machinability and Surface characteristics of a Shape Memory Alloy (SMA) Processed through Wire Electro Spark Erosion Method, Arch. Metall. Mater., 2022, 67(3), p 921–930.
M. Azam, M. Jahanzaib, J.A. Abbasi, M. Abbas, A. Wasim, and S. Hussain, Parametric Analysis of Recast Layer Formation in Wire-Cut EDM of HSLA Steel, J. Adv. Manuf. Technol., 2016, 87, p 713–722.
T. Suresh, K. Jayakumar, G. Selvakumar, and S.R. Prakash, Comparative Machining Characteristics Studies on SS 304 using Coated and Uncoated Brass Wire through Wire EDM, La Metall. Ital., p 32-42
L. Li, Y.B. Guo, X.T. Wei, and W. Li, Surface Integrity Characteristics in Wire-EDM of Inconel 718 at Different Discharge Energy, Proc. CIRP, 2013, 6, p 220–225.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Hosalli, R., Shanmuganatan, S.P. & Madhusudan, M. Performance Studies on the Wire Electric Discharge Machining Characteristics of Stellite-6B Superalloys. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09533-0
Received:
Revised:
Accepted:
Published:
DOI: https://doi.org/10.1007/s11665-024-09533-0