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Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel

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Abstract

The present study analyzed the effects of cold treated brass wire electrode for the machining of hardened high-strength low-alloy (HSLA) steel on wire electric discharge machine. Cold treatment of brass wire at − 70 °C for 24 h has refined its microstructure which results in an increase in electrical conductivity by 24.5%. The experimental work is designed using fractional factorial design to determine the relationship of input variables including servo voltage (SV), pulse on time (Ton), pulse off time (Toff), wire type (Wt), wire tension (Tw), and flushing pressure (Fp) and response measures including cutting speed (CS), surface roughness (Ra), and kerf width (Kf). In Wt, two kinds of brass wires including cold treated (CT) and non-cold treated (NCT) have been used. Empirical models for cutting speed (CS), surface roughness (Ra), and kerf width (Kf) are developed, and their contribution is analyzed through the analysis of variance (ANOVA) technique. Desirability function offers the best combination of input variables to maximize CS and minimize both Ra and Kf simultaneously. Ton is observed as the most effective input variable for all response measures, followed by Wt and Toff. CT brass wire has been observed as the best alternative in multi-objective optimization.

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Abbreviations

WEDM:

Wire electric discharge machining

ECM:

Electric chemical machining

WJM:

Water jet machining

HSLA:

High-speed low alloy

ANOVA:

Analysis of variance

SV:

Servo voltage

T on :

Pulse on time

T off :

Pulse off time

W t :

Wire type

T w :

Wire tension

F p :

Flushing pressure

CT:

Cold treated

NCT:

Non-cold treated

CS:

Cutting speed

Ra:

Surface roughness

Kf:

Kerf width

I :

Discharge current

C :

Capacitance

MRR:

Material removal rate

SS:

Sum of square

df :

Degree of freedom

MS:

Mean square

R 2 :

Coefficient of determination

C.V:

Coefficient of variation

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Authors and Affiliations

  1. Industrial Engineering Department, University of Engineering and Technology Taxila, Taxila, Pakistan

    Waseem Tahir & Mirza Jahanzaib

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  1. Waseem Tahir
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  2. Mirza Jahanzaib
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Correspondence to Waseem Tahir.

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Technical Editor: Marcelo Areias Trindade.

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Tahir, W., Jahanzaib, M. Multi-objective optimization of WEDM using cold treated brass wire for HSLA hardened steel. J Braz. Soc. Mech. Sci. Eng. 41, 525 (2019). https://doi.org/10.1007/s40430-019-2028-9

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