Skip to main content
SpringerLink
Log in

Investigation and Optimization of Cutting Performance of High Chrome White Cast Iron by Wire Erosion

  • Research Article-Mechanical Engineering
  • Published:
Arabian Journal for Science and Engineering Aims and scope Submit manuscript

Abstract

Wire electric discharge machining (WEDM) is an emerging approach to producing more accurate and precise complex products in the unconventional machining process. The WEDM process is affected by several process factors. Therefore, the appropriate combination of process factors is required to achieve economical and quality machining. Machining is very difficult due to the presence of chromium carbide in the structure of high-Cr white cast irons (HCCIs) with 12–17% Cr content in machining processes. Therefore, the machinability of HCCIs has always been a disadvantage. In this study, specially molded HCCIs samples were subjected to softening, casting (not heat treated) and hardened heat treatment processes, respectively. We aimed to experimentally investigated the changes in HCCIs samples characteristics, pulse on time, pulse of time, wire speed, and cutting performance in the WEDM process in this study. The L18 orthogonal array was used using the Taguchi method, and an experimental study was prepared. Afterward, an optimization study was carried out using mathematical models for WEDM with the help of performance outputs via ANOVA analysis. The experimental performances examined in this study are material removal rate and surface roughness. The experimental study determined that the material removal rate and surface roughness increased when the pulse on time increased. Later, machined samples morphological and structures properties were analyzed X-ray spectroscopy (EDS), scanning electron microscopy, microhardness and surface roughness. Furthermore, electrical conductivity of them was measured.

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

Access this article

Log in via an institution

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

Similar content being viewed by others

Abbreviations

ANOVA:

Analysis of variance

WEDM:

Wire Electrical discharge machining

MRR:

Material removal rate (g/min)

Ton :

Pulse on time (µ\(\mathrm{s})\)

Toff :

Pulse off time (µ\(\mathrm{s})\)

WF:

Wire feed (m/s)

SEM:

Scanning electron microscope

Ra:

Surface roughness (µ\(\mathrm{m})\)

HCCI:

High Cr white cast iron

References

  1. Pramanik, A.; Basak, A.K.; Prakash, C.: Understanding the wire electrical discharge machining of Ti6Al4V alloy. Heliyon 5, e01473 (2019). https://doi.org/10.1016/j.heliyon.2019.e01473

    Article  CAS  PubMed  PubMed Central  Google Scholar 

  2. Ugrasen, G.; Ravindra, H.V.; Prakash, G.V.N.; Keshavamurthy, R.: Process optimization and estimation of machining performances using artificial neural network in wire EDM. Procedia Mater. Sci. 6, 1752–1760 (2014). https://doi.org/10.1016/j.mspro.2014.07.205

    Article  CAS  Google Scholar 

  3. Gore, A.S.; Patil, N.G.: Wire electro discharge machining of metal matrix composites: a review. Procedia Manuf. 20, 41–52 (2018). https://doi.org/10.1016/j.promfg.2018.02.006

    Article  Google Scholar 

  4. Saha, S.; Pachon, M.; Ghoshal, A.; Schulz, M.J.: Finite element modeling and optimization to prevent wire breakage in electro-discharge machining. Mech. Res. Commun. 31, 451–463 (2004). https://doi.org/10.1016/j.mechrescom.2003.09.006

    Article  Google Scholar 

  5. Chaudhary, A.; Sharma, S.; Verma, A.: WEDM machining of heat treated ASSAB’88 tool steel: a comprehensive experimental analysis. Mater. Today Proc. 50, 946–951 (2021). https://doi.org/10.1016/j.matpr.2021.06.354

    Article  CAS  Google Scholar 

  6. Aggarwal, V.; Pruncu, C.I.; Singh, J.; Sharma, S.; Pimenov, D.Y.: Empirical investigations during WEDM of Ni-27Cu-3.15Al-2Fe-1.5Mn based superalloy for high temperature corrosion resistance applications. Materials (Basel). 13, 1–16 (2020). https://doi.org/10.3390/MA13163470

    Article  Google Scholar 

  7. Ehsan Asgar, M.; Singh Singholi, A.K.: Parameter study and optimization of WEDM process: a Review. IOP Conf. Ser. Mater. Sci. Eng. (2018). https://doi.org/10.1088/1757-899X/404/1/012007

    Article  Google Scholar 

  8. Shivade, A.S.; Shinde, V.D.: Multi-objective optimization in WEDM of D3 tool steel using integrated approach of Taguchi method & Grey relational analysis. J. Ind. Eng. Int. 10, 149–162 (2014). https://doi.org/10.1007/s40092-014-0081-7

    Article  Google Scholar 

  9. Lokeswara Rao, T.; Selvaraj, N.: Optimization of WEDM process parameters on titanium alloy using Taguchi method. Int. J. Mod. Eng. Res. 3, 2281–2286 (2013)

    Google Scholar 

  10. Dinesh, S.; Pillai, T.P.; Parthiban, A.; Rajaguru, K.: Modelling of WEDM process for machining ASTM 52100 steel. Mater. Today Proc. 37, 1103–1106 (2020). https://doi.org/10.1016/j.matpr.2020.06.343

    Article  CAS  Google Scholar 

  11. Rajmohan, K.; Kumar, A.S.: Experimental investigation and prediction of optimum process parameters of micro-wire-cut EDM of 2205 DSS. Int. J. Adv. Manuf. Technol. 93, 187–201 (2017). https://doi.org/10.1007/s00170-016-8615-3

    Article  Google Scholar 

  12. Takayama, Y.; Makino, Y.; Niu, Y.; Uchida, H.: The latest technology of wire-cut EDM. Procedia CIRP. 42, 623–626 (2016). https://doi.org/10.1016/j.procir.2016.02.259

    Article  Google Scholar 

  13. Dzionk, S.; Siemiatkowski, M.S.: Studying the effect of working conditions on WEDM machining performance of super alloy inconel 617. Machines. (2020). https://doi.org/10.3390/MACHINES8030054

    Article  Google Scholar 

  14. Somashekhar, K.P.; Mathew, J.; Ramachandran, N.: A feasibility approach by simulated annealing on optimization of micro-wire electric discharge machining parameters. Int. J. Adv. Manuf. Technol. 61, 1209–1213 (2012). https://doi.org/10.1007/s00170-012-4096-1

    Article  Google Scholar 

  15. Mostafapor, A.; Vahedi, H.: Wire electrical discharge machining of AZ91 magnesium alloy; investigation of effect of process input parameters on performance characteristics. Eng. Res. Express. (2019). https://doi.org/10.1088/2631-8695/ab26c8

    Article  Google Scholar 

  16. Urtekin, L.; Özerkan, H.B.; Cogun, C.; Genc, A.; Esen, Z.; Bozkurt, F.: Experimental investigation on wire electric discharge machining of biodegradable AZ91 Mg alloy. J. Mater. Eng. Perform. 30, 7752–7761 (2021). https://doi.org/10.1007/s11665-021-05939-2

    Article  CAS  Google Scholar 

  17. Sarkar, S.; Ghosh, K.; Mitra, S.; Bhattacharyya, B.: An integrated approach to optimization of WEDM combining single-pass and multipass cutting operation. Mater. Manuf. Process. 25, 799–807 (2010). https://doi.org/10.1080/10426910903575848

    Article  CAS  Google Scholar 

  18. Basavaraju, H.R.; Suresh, R.; Manjunath, S.S.; Janardhan, L.: Study on effect of process parameters on MRR and surface roughness in wire electrical discharge machining of titanium grade 7 alloy. Mater. Today Proc. 47, 2481–2485 (2021). https://doi.org/10.1016/j.matpr.2021.04.555

    Article  CAS  Google Scholar 

  19. Mahapatra, S.S.; Patnaik, A.: Parametric optimization of wire electrical discharge machining (WEDM) process using taguchi method. J. Braz. Soc. Mech. Sci. Eng. 28, 422–429 (2006). https://doi.org/10.1590/S1678-58782006000400006

    Article  Google Scholar 

  20. Manjaiah, M.; Laubscher, R.F.; Kumar, A.; Basavarajappa, S.: Parametric optimization of MRR and surface roughness in wire electro discharge machining (WEDM) of D2 steel using Taguchi-based utility approach. Int. J. Mech. Mater. Eng. (2016). https://doi.org/10.1186/s40712-016-0060-4

    Article  Google Scholar 

  21. Saha, S.; Maity, S.R.; Dey, S.: Machinability study of A286 superalloy for complex profile generation through wire electric discharge machining. Arab. J. Sci. Eng. 48, 3241–3253 (2022). https://doi.org/10.1007/s13369-022-07028-5

    Article  CAS  Google Scholar 

  22. Sibalija, T.V.; Kumar, S.; Patel, G.C.M.: Jagadish: a soft computing-based study on WEDM optimization in processing Inconel 625. Neural Comput. Appl. 33, 11985–12006 (2021). https://doi.org/10.1007/s00521-021-05844-8

    Article  Google Scholar 

  23. Pramanik, A.; Islam, M.N.; Basak, A.K.; Dong, Y.; Littlefair, G.; Prakash, C.: Optimizing dimensional accuracy of titanium alloy features produced by wire electrical discharge machining. Mater. Manuf. Process. 34, 1083–1090 (2019). https://doi.org/10.1080/10426914.2019.1628259

    Article  CAS  Google Scholar 

  24. Goswami, A.; Kumar, J.: Trim cut machining and surface integrity analysis of Nimonic 80A alloy using wire cut EDM. Eng. Sci. Technol. Int. J. 20, 175–186 (2017). https://doi.org/10.1016/j.jestch.2016.09.016

    Article  Google Scholar 

  25. Lodhi, B.K.; Agarwal, S.: Optimization of machining parameters in WEDM of AISI D3 steel using taguchi technique. Procedia CIRP. 14, 194–199 (2014). https://doi.org/10.1016/j.procir.2014.03.080

    Article  Google Scholar 

  26. Majumder, H.; Maity, K.: Application of GRNN and multivariate hybrid approach to predict and optimize WEDM responses for Ni-Ti shape memory alloy. Appl. Soft Comput. J. 70, 665–679 (2018). https://doi.org/10.1016/j.asoc.2018.06.026

    Article  Google Scholar 

  27. Kumar, M.; Manna, A.; Mangal, S.K.; Malik, A.: An experimental investigation during wire electrical discharge machining of Al/SiC-MMC. In: Khangura, S., Singh, P., Singh, H., Brar, G. (eds.) Proceedings of the International Conference on Research and Innovations in Mechanical Engineering. Lecture Notes in Mechanical Engineering, pp. 261–271. Springer, New Delhi (2014). https://doi.org/10.1007/978-81-322-1859-3_24

  28. Wasif, M.; Ahmed Khan, Y.; Zulqarnain, A.; Amir Iqbal, S.: Analysis and optimization of wire electro-discharge machining process parameters for the efficient cutting of aluminum 5454 alloy. Alex. Eng. J. 61, 6191–6203 (2022). https://doi.org/10.1016/j.aej.2021.11.048

    Article  Google Scholar 

  29. Mandal, K.; Sarkar, S.; Mitra, S.; Bose, D.: Parametric analysis and GRA approach in WEDM of Al 7075 alloy. Mater. Today Proc. 26, 660–664 (2019). https://doi.org/10.1016/j.matpr.2019.12.361

    Article  CAS  Google Scholar 

  30. Pei, Y.; Song, R.; Zhang, Y.; Huang, L.; Cai, C.; Wen, E.; Zhao, Z.; Yu, P.; Quan, S.; Su, S.; Chen, C.: The relationship between fracture mechanism and substructures of primary M7C3 under the hot compression process of self-healing hypereutectic high chromium cast iron. Mater. Sci. Eng. A. 779, 139150 (2020). https://doi.org/10.1016/j.msea.2020.139150

    Article  CAS  Google Scholar 

  31. Kaya, S.; Yılan, F.; Urtekin, L.: Influences of Cr on the microstructural, wear and mechanical performance of high-chromium white cast iron grinding balls. J. Mater. Manuf. (2022). https://doi.org/10.5281/zenodo.7107351

  32. Manikandan, K.; Ranjith Kumar, P.; Raj Kumar, D.; Palanikumar, K.: Machinability evaluation and comparison of Incoloy 825, Inconel 603 XL, Monel K400 and Inconel 600 super alloys in wire electrical discharge machining. J. Mater. Res. Technol. 9, 12260–12272 (2020). https://doi.org/10.1016/j.jmrt.2020.08.049

    Article  CAS  Google Scholar 

  33. Suresh, T.; Jayakumar, K.; Selvakumar, G.; Ramprakash, S.: Experimental investigation on improvement of machinability of SS 304 through multipass cutting in WEDM. Arab. J. Sci. Eng. (2022). https://doi.org/10.1007/s13369-022-07508-8

    Article  Google Scholar 

  34. Kuo, H.C.; Wu, J.L.: A new approach with orthogonal array for global optimization in design of experiments. J. Glob. Optim. 44, 563–578 (2009). https://doi.org/10.1007/s10898-008-9357-z

    Article  MathSciNet  Google Scholar 

Download references

Acknowledgements

The authors would like to thank Kütahya Dumlupınar University Advanced Technologies Center (ILTEM) for their valuable assistance.

Author information

Authors and Affiliations

  1. Faculty of Engineering and Architecture, Department of Mechanical Engineering, Kırşehir Ahi Evran University, Kirsehir, Turkey

    Levent Urtekin, İbrahim Baki Şahin, Faik Yılan & Erkan Kuloğlu

  2. Machinery and Metal Technology Department, Gazi University, Ankara, Turkey

    Asım Genç

Authors
  1. Levent Urtekin
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. İbrahim Baki Şahin
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Faik Yılan
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Erkan Kuloğlu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Asım Genç
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Faik Yılan.

Ethics declarations

Conflict of interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Urtekin, L., Şahin, İ.B., Yılan, F. et al. Investigation and Optimization of Cutting Performance of High Chrome White Cast Iron by Wire Erosion. Arab J Sci Eng 49, 1585–1596 (2024). https://doi.org/10.1007/s13369-023-07930-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13369-023-07930-6

Keywords

Search

Navigation