Optimization of wire electrical discharge turning process: trade-off between production rate and fatigue life
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ORIGINAL ARTICLE
Optimization of wire electrical discharge turning process: trade-off between production rate and fatigue life Pouyan Talebizadehsardari 1,2 & Arameh Eyvazian 3 & Farayi Musharavati 3 & Qasim Zeeshan 4 & Roohollah Babaei Mahani 5,6 & Tamer A. Sebaey 7,8 Received: 9 September 2020 / Accepted: 2 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Turning by wire electrical discharge machining (WEDT) has been proven as a successful cutting process for producing complex geometries in difficult-to-cut round bars. However, effects of the process factors on fatigue life and surface integrity have not been studied well. For the first time, in the present investigation it is studied how the WEDT factors influence the surface integrity and subsequent fatigue life of Inconel 718. Experiments were carried out using response surface design taking discharge current, pulse on time, and spindle speed into account as influential parameters. Variation of fatigue life was analyzed and dissuaded by residual stress and surface roughness. Analyses of variance have been taken into account as influential parameters. Finally, a series of optimization results were obtained to understand the trend of fatigue life and material removal rate in Pareto front graphs. Among the obtained results, the one with satisfaction of both responses was compared with the fatigue life and surface integrity of In718 fabricated by the conventional turning process. Results indicated that the fatigue life of parameters at optimum processing conditions (i.e., current of 5 A, pulse time of 1000, and fatigue spindle speed of 250 RPM) can be competitive with finish turning of Inconel 718. Keywords Wire electrical discharge turning . Surface integrity . Fatigue life . Parametric influence
1 Introduction Hard material such as nickel-based upper alloy has been extensively spreading in rotating parts of jet engine and aircraft manufacturing [1]. The main reason for this widespread application is maintenance of its properties in a harsh environment. However, the main problem associated with this type of alloy is poor machinability with a conventional machining process * Roohollah Babaei Mahani [email protected]
that results in excessive tool wear and damaged surface integrity. The former leads to reduction of tool life, while the latter makes the use of sequential surface treatment necessary. Both of them result in increased production costs. As an applicable method, non-conventional machining processes such as electrical discharge machining (EDM) can be effectively used for processing of In718 [2, 3]. The process enables to remove material independent of its hardness and 4
Department of Mechanical Engineering, Eastern Mediterranean University, via Mersin 10, Famagusta, North Cyprus, Turkey
5
Institute of Research and Development, Duy Tan University, Da Nang 550000, Vietnam
6
Faculty of Civil Engineering, Duy Tan University, Da Nang 550000, Vietnam
7
Engineering Management Department, College of E
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