Optimization of process parameters during WEDM of EN-42 spring steel
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Optimization of process parameters during WEDM of EN‑42 spring steel Lalta Prasad1 · Manish Upreti2 · Anshul Yadav3 · Raj Vardhan Patel4 · Virendra Kumar5 · Anil Kumar5 Received: 11 July 2019 / Accepted: 30 March 2020 © Springer Nature Switzerland AG 2020
Abstract The present work aimed to carry out the machining of EN-42 spring steel in wire electrical discharge machining with zinc-coated brass wire using distilled water as a dielectric medium. The effect of WS2 powder added in a dielectric medium, on the metal removal rate and surface roughness has been evaluated. With the use of WS2, the conductivity of the dielectric is found to be constantly equal to 10 S/m, which is a very promising feature. WS2 enhances dielectric life, metal removal rate, and surface roughness significantly. The effect of cryogenically treated wire on the metal removal rate and surface roughness during machining has been carried out. Taguchi method and genetic algorithm were used to optimize machining performance measures. Both methods provide optimum parameters and target value. The results of the Taguchi method show more error as compared to the genetic algorithm. The on time can be predicted as the most significant parameter according to the Taguchi method. From the results, it is observed that higher on time shows better metal removal rate and lower on time shows a better surface finish. Keywords Cryogenic treatment · Metal removal rate · Root mean square surface roughness · Taguchi · S-method · Genetic algorithm · EN-42 spring steel Abbreviations EDM Electrical discharge machining TWR Tool wear rate ASTM American society for testing and materials S/N Signal to noise ratio WEDM Wire electrical discharge machining Notations Ton On time, µS Toff Off time, µS Fwf Wired feed, M/min Fsf Servo feed, M/min MRR Material removal rate, m3/min
1 Introduction Wire electrical discharge machining (WEDM) process can be used to machine metal (soft or hard) with good dimensional accuracy with the help of electrical spark formed between the workpiece and the electrode which is in the shape of the required contour. The WEDM is the thermal non-conventional method used for complex shape material’s machining. The electric discharge or spark erosion of the metallic electrode (positive and negative charge) is the basic principle of electrical discharge machining (EDM). The tool’s active part is immersed entirely in a fluid
Electronic supplementary material The online version of this article (https://doi.org/10.1007/s42452-020-2650-2) contains supplementary material, which is available to authorized users. * Anshul Yadav, [email protected] | 1Department of Mechanical Engineering, National Institute of Technology Uttarakhand, Srinagar, Uttarakhand 246174, India. 2Department of Mechanical Engineering, G. B. Pant Engineering College, Pauri Garhwal, Uttarakhand 246194, India. 3Department of Mechanical Engineering, Indian Institute of Technology, Kanpur, Uttar Pradesh 208016, India. 4Department of Mechanical Engineering, Sherwood Coll
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