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Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire

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Abstract

DC53 is considered as superior steel grade by die and mold making industries as compared to D2 and D3 steel due to its excellent mechanical characteristics like high hardness, wear resistance and strength. DC53 steel finds applications in making stamping dies, punches and cutting tools. In wire electric discharge machining (WEDM) process, gamma phase coated wire offers superior machining performance over uncoated brass and zinc coated electrode wires. This work was performed to study the effect of machining variables like sparks on duration, sparks off duration, arc-on time, and servo voltage on response variables, namely kerf width (KW), cutting speed (CS), material removal rate (MRR), and surface roughness (Ra) for WEDM of DC53 steel. Taguchi L18 orthogonal array was used for experimental design. Analysis of variance showed that sparks on duration is the most significant factor affecting KW, CS, and MRR with percentage contribution of 48.25 %, 80.21 %, and 45.21 %, respectively. Optimal set of machining parameters resulted in 14.02 % improvement in MRR and 19.24 % reduction in workpiece surface roughness. Moreover, gamma phase coated wire was found to have 30–35 % faster cutting rate as compared to uncoated brass wire.

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Acknowledgments

This manuscript is based on an M.Sc. Manufacturing Engineering thesis titled “Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire” submitted by Mudassar Rehman to University of Engineering and Technology Lahore, Pakistan.

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Authors and Affiliations

  1. School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, China

    Mudassar Rehman

  2. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Sarmad Ali Khan & Rakhshanda Naveed

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  1. Mudassar Rehman
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  2. Sarmad Ali Khan
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  3. Rakhshanda Naveed
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Correspondence to Mudassar Rehman.

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Recommended by Editor Chongdu Cho

Mudassar Rehman is a Research Scholar in Mechanical Engineering, Northwestern Polytechnical University, Xian, China. He received his B.Sc. and M.Sc. in Manufacturing Engineering from University of Engineering & Technology (UET), Lahore, Pakistan. His research interests include advanced materials processing, advanced manufacturing processes and additive manufacturing.

Sarmad Ali Khan is an Assistant Professor of Industrial & Manufacturing Engineering, UET, Lahore, Pakistan. His Ph.D. is in Manufacturing Engineering from University of Birmingham, UK. His research interests include conventional and non-conventional machining, and advanced manufacturing processes.

Rakhshanda Naveed is an Assistant Professor of Industrial & Manufacturing Engineering, University of Engineering & Technology (UET), Lahore, Pakistan. Her Ph.D. is in Manufacturing Engineering from UET, Lahore, Pakistan. Her research interests include conventional and non-conventional machining processes.

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Rehman, M., Khan, S.A. & Naveed, R. Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire. J Mech Sci Technol 34, 2767–2773 (2020). https://doi.org/10.1007/s12206-020-0609-2

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  • DOI: https://doi.org/10.1007/s12206-020-0609-2

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