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Statistical modelling and analysis of material removal rate and surface roughness during wire electrical discharge hybrid turning (WEDHT) process

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Abstract

The non-traditional machining process is highly recommended for machining difficult-to-cut materials with increased hardness, toughness, work hardening effect, and poor thermal diffusivity, etc. Wire electrical discharge machining (Wire-EDM) is one of the above said processes used to machine material which are electrically conductive. One of the variants of Wire-EDM process is wire electrical discharge hybrid turning (WEDHT) process, in which, the work material is made to rotate during material removal resulting in cylindrical components manufacturing. This process follows the principle of sparking and erosion for material removal with moving wire as a tool electrode. In the present study, WEDHT process is performed on Ti-6Al-4V alloy, which has applications in the areas of biomedical, marine, chemical, aerospace, etc. 27 experiments are performed using diffusion annealed zinc coated brass wire as the tool electrode by varying servo feed, pulse ON time and wire feed rate at three different levels to study the surface quality and material removal as the output performances. Atomic force microscopy (AFM) technique gives a 3D profile of the machined surface and measures the surface roughness. These measured 3D results are validated once again in 2D surface profile meter. The factor effects of all three input parameters are analyzed individually and analysis of variance (ANOVA) for all the performance responses are studied to know the most contributing factor in deciding the surface roughness (SR) and material removal, respectively. The regression analysis is performed for the response measures and the model parameters are analysed for goodness of fit using residual plot. Pulse ON time contributes more in deciding the SR and material removal rate (MRR) of the component followed by servo feed and wire feed rate. The interaction effects of the parameters are found to be insignificant.

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Abbreviations

AFM:

Atomic force microscopy

ANOVA:

Analysis of variance

DoF:

Degrees of freedom

EDM:

Electrical discharge machining

MRR:

Material removal rate

MS:

Mean square

SR:

Surface roughness

SS:

Sum of square

WEDHT:

Wire electrical discharge hybrid turning

Mt :

Machining time (min)

Sf :

Servo Feed (mm/min)

TON :

Pulse ON time (µs)

Wf :

Wire feed rate (m/min)

mi :

Sample weight prior machining (gm)

mf :

Sample weight post machining (gm)

m/min:

Metre per minute

mm/min:

Millimetre per minute

ρ:

Density (gm/mm3)

µs:

Microseconds

µm:

Micrometre

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Acknowledgement

The authors thank Vellore Institute of Technology (VIT), Vellore for providing “VIT SEED GRANT” for carrying out this research work. Authors are also thankful to the advanced materials processing and testing (AMPT) Laboratoy of VIT, Vellore for providing the roughness profiler (Mahr Surf).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Saveetha School of Engineering, SIMATS, Chennai, 602105, India

    M Vignesh

  2. Centre for Innovative Manufacturing Research, School of Mechanical Engineering (SMEC), Vellore Institute of Technology, Vellore, 632014, India

    R Ramanujam

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  1. M Vignesh
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  2. R Ramanujam
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Correspondence to R Ramanujam.

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Vignesh, M., Ramanujam, R. Statistical modelling and analysis of material removal rate and surface roughness during wire electrical discharge hybrid turning (WEDHT) process. Sādhanā 46, 73 (2021). https://doi.org/10.1007/s12046-021-01597-1

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  • DOI: https://doi.org/10.1007/s12046-021-01597-1

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