WEDM Process Parameters Analysis and Optimization: A REVIEW

Authors

  • Huda Anwar Production Engineering and Metallurgy Department / University of Technology Baghdad-Iraq Author
  • Dr.Saad K. Shather Production Engineering and Metallurgy Department / University of Technology Baghdad-Iraq. Author
  • Waqass S. Khudhir Production Engineering and Metallurgy Department / University of Technology Baghdad-Iraq Author

DOI:

https://doi.org/10.56294/sctconf2024860

Keywords:

WEDM, Parameters for Enhancing Performance, Various Optimization Techniques, Analysis of Variance (ANOVA)

Abstract

Wire Electrical Discharge Machining (WEDM) represents a non-conventional machining approach that harnesses thermal electrical energy for the fabrication of intricate structures. WEDM machines excel in achieving precise dimensions and a polished surface finish. It finds frequent application in the machining of robust materials that pose challenges for conventional manufacturing methods due to issues like vibrations. Within this machining method, numerous process parameters and performance indicators come into play, prompting various studies and investigations into its intricacies. This paper presents a comprehensive overview of current research trends in WEDM, particularly focusing on parameters for enhancing performance, such as surface roughness (SR), material removal rate (MRR), and Kerf width (KW). Notably, several process parameters, including pulse-off-time (TOFF), servo voltage (SV), pulse-on-time (TON), peak current (I), and wire tension (WT), contribute to the WEDM process. Additionally, various optimization techniques like the Taguchi method, Grey Relation Analysis (GRA), and analysis of variance (ANOVA) are employed across diverse materials, encompassing alloys, superalloys, and composites. The findings of this study suggest the importance of considering various process parameters, such as pulse-off-time (TOFF), servo voltage (SV), pulse-on-time (TON), peak current (I), and wire tension (WT), in the WEDM process. Moreover, the application of optimization techniques like the Taguchi method, Grey Relation Analysis (GRA), and analysis of variance (ANOVA) is recommended. These recommendations aim to improve the understanding and optimization of WEDM processes, especially when applied to diverse materials, including alloys, superalloys, and composites

References

1. Kapoor, Jatinder, Sehijpal Singh, and Jaimal Singh Khamba. "High-performance wire electrodes for wire electrical-discharge machining–a review." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 226.11 (2012): 1757-1773.‏

2. Sharma, Neeraj, Rajesh Khanna, and Rahuldev Gupta. "Multi quality characteristics of WEDM process parameters with RSM." Procedia Engineering 64 (2013): 710-719.‏

3. Sahoo, Sarat Kumar, Sunita Singh Naik, and Jaydev Rana. "Optimisation of WEDM process parameters during machining of HCHCr steel using TOPSIS method." International Journal of Process Management and Benchmarking 9.2 (2019): 216-231.‏

4. Singh, Harvinder, Vinod Kumar, and Jatinder Kapoor. "Multi-response optimization of WEDM process parameters during the fabrication of microchannels for industrial applications." Materials Today: Proceedings 46 (2021): 81-88.‏

5. Singh, Hari, and R. Garg. "Effects of process parameters on material removal rate in WEDM." Journal of achievements in materials and manufacturing engineering 32.1 (2009): 70-74.‏

6. Mahapatra, S. S., and Amar Patnaik. "Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method." The International Journal of Advanced Manufacturing Technology 34 (2007): 911-925.‏

7. Kumar, Rajender, Puneet Katyal, and Shiwani Mandhania. “Grey relational analysis based multiresponse optimization for WEDM of ZE41A magnesium alloy.” International Journal of Lightweight Materials and Manufacture 5.4 (2022): 543-554.‏

8. Ehsan Asgar, M., & Singh Singholi, A. K. (2018, September). Parameter study and optimization of WEDM process: A Review. In Iop conference series: Materials science and engineering (Vol. 404, p. 012007). IOP Publishing.‏

9. Boujelbene, M., Ezzdini, S., Elboughdiri, N., Salem, W. B., & Youssef, W. (2017). Investigation on the surface roughness of the high steel material after wire electrical discharge machining process. International Journal of Advanced and Applied Sciences, 4(5), 130-136.

10. Shather, Saad Kariem, Abbas Fadhil Ibrahim, and Diana Abed al kareem Noori. "Experimental investigation to predict metal removal and surface roughness in wire cut process." Diyala Journal of Engineering Sciences (2016): 49-58

11. Rathod, L., N. S. Poonawala, and R. Rudrapati. "Multi response optimization in WEDM of H13 steel using hybrid optimization approach." IOP Conference Series: Materials Science and Engineering. Vol. 814. No. 1. IOP Publishing, 2020.‏

12. Patel, Vijay D., and Rajeev V. Vaghmare. "A review of recent work in wire electrical discharge machining (WEDM)." International Journal of Engineering Research and Applications 3.3 (2013): 805-816.‏

13. Complete EDM handbook compliments of www.reliable EDM. Com

14. Aidil, A. R. M., M. Minhat, and N. I. S. Hussein. "Current research trends in wire electrical discharge machining (WEDM): a review." Journal of Advanced Manufacturing Technology (JAMT) 12.1 (1) (2018): 11-24

15. Ali, Muayad M., and Abbas F. Ibrahim. "Effect of machining parameters on surface roughness and metal removal rate for AISI 310 L stainless steel in WEDM." Engineering and Technology Journal 40.01 (2022): 181-188.‏

16. Kumar, Anish, Dr Vinod Kumar, and Dr Jatinder Kumar. "A review on the state of the art in wire electric discharge machining (WEDM) process." International Journal of Mechanical Engineering Research and Development (IJMERD) 1.1 (2011).‏

17. Khan, Z. A., Siddiquee, A. N., Khan, N. Z., Khan, U., & Quadir, G. A. (2014). Multi response optimization of wire electrical discharge machining process parameters using Taguchi based grey relational analysis. Procedia Materials Science, 6, 1683-1695.‏

18. Bobbili, R., Madhu, V., & Gogia, A. K. (2015). Multi response optimization of wire-EDM process parameters of ballistic grade aluminium alloy. Engineering science and technology, an international journal, 18(4), 720-726

19. Priyan, M. Shunmuga, et al., "Investigation of surface roughness and MRR on stainless steel machined by wire EDM." International Journal of Engineering Research and Technology 5.3 (2016).

20. ‏Thi Hong, T., Do Tam, T., Nguyen, M. C., Anh Tung, L., Ngoc Pi, V., Le Ky, H., & Tien Dung, H. (2019). Effects of process parameters on surface roughness in wire-cut EDM of 9CRSI tool steel. International Journal of Mechanical Engineering and Technology, 10(3).‏

21. El-Bahloul, S. A. (2020). Optimization of wire electrical discharge machining using statistical methods coupled with artificial intelligence techniques and soft computing. SN Applied Sciences, 2, 1-8.‏

22. Hema, P., & Aparna, K. (2021, April). Process parameter optimization of wire EDM on weldment of Monel 400 and AISI 316 grade steel. In IOP Conference Series: Materials Science and Engineering (Vol. 1132, No. 1, p. 012027). IOP Publishing.‏

23. Murali, G., Murugan, M., Arunkumar, K., Elumalai, P. V., Mohanraj, D., & Prabhakar, S. (2022). Investigation and Process Parameter Optimization on Wire Electric Discharge Machining of Aluminium 6082 Alloy. Advances in Materials Science and Engineering, 2022.‏

24. Rao, C. M., & Subbaiah, K. V. Optimization of Wire EDM Process Parameters in Machining SS316 Using DEAR Method (.‏2021)

25. Sapit, Azwan, Shather, Saad, & Nehad, Farook. (2021). Parameters analysis in wire electric discharge machine process of titanium alloys with dielectric alumina. Journal of Materials Today: Proceedings, 10.1016/J.matpr.2020.12.216

26. Jha, Mukulanand, Rajiv Kumar Garg, & Shekhar Shrivastava. "Experimental investigation and optimization of WEDM process for AISI 420 stainless steel." IOP Conference Series: Materials Science and Engineering. Vol. 1259. No. 1. IOP Publishing, 2022.‏

27. Uday Kiran Kandala, A. V., Solomon, D. G., & Arulraj, J. J. (2022). Advantages of taguchi method compared to response surface methodology for achieving the best surface finish in wire electrical discharge machining (WEDM). Journal of Mechanical Engineering (JMechE), 19(1), 185-200.‏

28. Naeim, N., AbouEleaz, M. A., & Elkaseer, A. (2023). Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304. Materials, 16(3), 1022

29. SAIF, M., & Rawat, R. K. (2023). Investigation of aluminum alloy 6061 in Wire-EDM regarding surface roughness and material removal rate by adopting optimization techniques. Journal of Mechanical Engineering and Sciences, 9410-9420.‏

30. Hammami, D., Louati, S., Masmoudi, N., & Bradai, C. (2023). Influence of WEDM process parameters on aluminum alloy’s surface finish. The International Journal of Advanced Manufacturing Technology, 126(1-2), 453-469.‏

31. Devarasiddappa, D., M. Chandrasekaran, and R. Arunachalam. "Experimental investigation and parametric optimization for minimizing surface roughness during WEDM of Ti6Al4V alloy using modified TLBO algorithm." Journal of the Brazilian Society of Mechanical Sciences and Engineering 42 (2020): 1-18.‏

32. Kumar, Anish, Vinod Kumar, and Jatinder Kumar. "Multi-response optimization of process parameters based on response surface methodology for pure titanium using WEDM process." The International Journal of Advanced Manufacturing Technology 68 (2013): 2645-2668.‏

33. Das, P. P., Diyaley, S., Chakraborty, S., & Ghadai, R. K. (2019). Multi-objective optimization of wire electro discharge machining (WEDM) process parameters using grey-fuzzy approach. Periodica Polytechnica Mechanical Engineering, 63(1), 16-25.‏

34. Priyadarshini, M., Biswas, C. K., & Behera, A. (2019, February). Grey-Taguchi optimization of Wire-EDM parameters for P20 tool steel. In Proceedings of the 5th International Conference on Mechatronics and Robotics Engineering (pp. 5-8).‏

35. Pramanik, A., Basak, A. K., Dixit, A. R., & Chattopadhyaya, S. (2018). Processing of duplex stainless steel by WEDM. Materials and Manufacturing Processes, 33(14), 1559-1567

36. Chaudhary, Tina, et al., "multi-response optimization for Nimonic alloy miniature gear fabrication using wire electrical discharge machining." Advances in Mechanical Engineering 12.10 (2020): 1687814020967580

37. Kalyanakumar, S., Prabhu, L., Saravanan, M., & Imthiyas, A. (2020, December). Experimental investigation of MRR, RA of 304 stainless steel using WEDM. In IOP Conference Series: Materials Science and Engineering (Vol. 993, No. 1, p. 012035). IOP Publishing.‏

38. Basavaraju, H. R., S. S. Manjunatha, and R. Suresh. "Investigation on Surface Roughness and MRR in WEDM of Titanium Grade 7 (Ti-0.15 Pd) Alloy using Statistical Techniques." Journal of Mechanical Engineering (1823-5514) 20.2 (2023).‏

39. Kumar, Pawan, Meenu Gupta, and Vineet Kumar. "Microstructural analysis and multi response optimization of WEDM of Inconel 825 using RSM based desirability approach." Journal of the Mechanical Behavior of Materials 28.1 (2019): 39-61.‏

40. Kumar, S. Suresh, Erdemir, F., Varol, Temel, Kumaran, S. Thirumalai, Uthayakumar, M., Canakci, Aykut (2020) Investigation of WEDM process parameters of Al–SiC–B4C composites using response surface methodology. International Journal of Lightweight Materials and Manufacture-3-2-127-135-2020.

41. Sridhar, Kandukuri, and G. Gopinath. "OPTIMIZATION OF PROCESS PARAMETERS FOR WIRE CUT EDM OF H-13 HOT DIE TOOL STEEL BY GREY RELATIONAL ANALYSIS."‏

42. Shinde, Babasaheb, and Raju Pawade. "Study on analysis of kerf width variation in WEDM of insulating zirconia." Materials and Manufacturing Processes 36.9 (2021): 1010-1018.‏

43. Ishfaq, K., Ahmad, N., Jawad, M., Ali, M. A., & M. Al-Ahmari, A. (2019). Evaluating material’s interaction in wire electrical discharge machining of stainless steel (304) for simultaneous optimization of conflicting responses. Materials, 12(12), 1940.‏

44. Bagal, D. K., Barua, A., Jeet, S., Satapathy, P., & Patnaik, D. (2019). MCDM optimization of parameters for wire-EDM machined stainless steel using hybrid RSM-TOPSIS, genetic algorithm and simulated annealing. Int J Eng Adv Technol, 9(1), 366-371.‏

45. Muniappan, A., C. Thiagarajan, and S. Somasundaram. "Optimization of kerf width obtained in WEDM of aluminum hybrid composite using Taguchi method." ARPN J. Eng. Appl. Sci 12 (2017): 382-388.‏

46. Ablyaz, T. R., Shlykov, E. S., Muratov, K. R., & Sidhu, S. S. (2021). Analysis of wire-cut electro discharge machining of polymer composite materials. Micromachines, 12(5), 571.‏

47. Pujara, J. M., K. D. Kothari, and A. V. Gohil. "An investigation of material removal rate and kerf on WEDM through grey relational analysis." Journal of Mechanical Engineering and Sciences 12.2 (2018): 3633-3644.‏

48. Nawaz, Y., Maqsood, S., Naeem, K., Nawaz, R., Omair, M., & Habib, T. (2020). Parametric optimization of material removal rate, surface roughness, and kerf width in high-speed wire electric discharge machining (HS-WEDM) of DC53 die steel. The International Journal of Advanced Manufacturing Technology, 107, 3231-3245.‏

49. Goyal, Ashish, and H. U. Z. E. F. Ur Rahman. "Experimental studies on Wire EDM for surface roughness and kerf width for shape memory alloy." Sādhanā 46.3 (2021): 160

50. Verma, Ramesh Kumar, Rajeev Kumar Upadhyay, and Syed Asghar Husain Rizvi. "Modeling of kerf width during WEDM of die steel D3." Materials Today: Proceedings 54 (2022): 832-838.‏

Downloads

Published

2024-01-01

How to Cite

1.
Anwar H, Shather DK, Khudhir WS. WEDM Process Parameters Analysis and Optimization: A REVIEW. Salud, Ciencia y Tecnología - Serie de Conferencias [Internet]. 2024 Jan. 1 [cited 2024 Dec. 12];3:860. Available from: https://conferencias.ageditor.ar/index.php/sctconf/article/view/912