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Evaluation of power consumption and MRR in WEDM of Ti–6Al–4V alloy and its simultaneous optimization for sustainable production

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Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Ti–6Al–4V is a popular titanium alloy, finding wide application mainly in aerospace and biomedical applications. Due to its high strength and toughness, wire cut electrical discharge machining (WEDM) is used for macro- and micro-machining of these materials. In this work, WEDM experiments on Ti–6Al–4V are conducted using Taguchi L16 OA with four process parameters, viz. pulse on time (Ton 13, 20, 27, 34 µs), pulse off time (Toff 4, 6, 8, 10 µs), current or applied current (I 1, 2, 4, 5 A) and wire speed (WS 350, 700, 1050, 1400 rpm). The novelty of this work is to evaluate two important sustainable measures, i.e., material removal rate (MRR) for economic concern and power consumption (PC) for environmental concern, in the production of WEDM components. The machining process cycle of WEDM process is described step by step. The power consumption during machining is evaluated by measuring line current using digital clamp meter. Regression models developed were found to be highly accurate with model accuracy of 98.34 and 94.03% for PC and MRR, respectively. Experimental investigation shows that I and Toff are found to be significant factors influencing MRR and PC. Parametric variation of response surface of MRR and PC is also studied using surface plots. SEM images of the machined surface at cutting conditions corresponding to maximum MRR and minimum PC are also studied. Desirability function analysis (DFA) is employed to simultaneously optimize the responses. The process parameters are optimized using DFA, and results show an improvement in composite desirability (CD) by 7.88% at optimum parameter setting of Ton 20 µs, Toff 6 µs, I 2 A and WS 1050 rpm. The performance measures at optimum parameter show improvement of 9.77 and 6.40% for MRR and PC, respectively.

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Acknowledgements

The authors acknowledge the financial support received from NERIST, Arunachal Pradesh, under TEQIP-II scheme and WEDM experimental facility at BMS College of Engineering, Bengaluru, in carrying out the research. The first author also acknowledges the support received from AICTE-NEQIP scheme of Rajiv Gandhi Govt. Polytechnic, Itanagar, Arunachal Pradesh.

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Authors and Affiliations

  1. North Eastern Regional Institute of Science and Technology, Nirjuli, Arunachal Pradesh, 791 111, India

    Devarasiddappa Devarajaiah & Chandrasekaran Muthumari

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  1. Devarasiddappa Devarajaiah
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  2. Chandrasekaran Muthumari
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Correspondence to Devarasiddappa Devarajaiah.

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Technical Editor: Márcio Bacci da Silva.

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Devarajaiah, D., Muthumari, C. Evaluation of power consumption and MRR in WEDM of Ti–6Al–4V alloy and its simultaneous optimization for sustainable production. J Braz. Soc. Mech. Sci. Eng. 40, 400 (2018). https://doi.org/10.1007/s40430-018-1318-y

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  • DOI: https://doi.org/10.1007/s40430-018-1318-y

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