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Experimental investigation and optimization of machining performance characteristics during WEDM of inconel 718: On evaluation of wire electrodes and advanced parameter techniques
Wire Electrical-Discharge-Machining (WEDM) is a well-known unconventional machining process to produce intricate shapes. However, obtaining a satisfactory WEDM cutting performance is indeed a challenging task during precision cutting. Hence, this investigation aims to attempt a favorable machining p...
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Published in: | Proceedings of the Institution of Mechanical Engineers. Part C, Journal of mechanical engineering science Journal of mechanical engineering science, 2022-02, Vol.236 (3), p.1645-1665 |
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Main Authors: | , |
Format: | Article |
Language: | English |
Subjects: | |
Citations: | Items that this one cites Items that cite this one |
Online Access: | Get full text |
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Summary: | Wire Electrical-Discharge-Machining (WEDM) is a well-known unconventional machining process to produce intricate shapes. However, obtaining a satisfactory WEDM cutting performance is indeed a challenging task during precision cutting. Hence, this investigation aims to attempt a favorable machining parameter setting in order to corner-cutting during WEDM for In-718. Here, machining performance characteristics have been considered based on corner deviation (CD) along with Material Removal Rate (MRR) and surface roughness (SR). Taguchi’s experiment design technique (L16) has been considered to run the experiments. The controllable process parameters are considered as Spark-on-time (Son), flushing-pressure (Fp), wire-tension (Tw), and discharge-current (Id). The aforesaid machining performance characteristics have been achieved through the two most popular wire electrodes, i.e., Zinc-coated brass electrode (Zn-BE) and Brass Wire Electrode (BWE), and compared the results. The comparison of performances by the wire electrodes on CD, MRR, and SR varied from 0.0286 mm to 0.0844 mm, 0.0045 g/min to 0.0214 g/min and 3.12 µm to 4.80 µm for BWE and 0.0218 mm to 0.0783 mm, 0.0090 g/min to 0.0342 g/min and 2.58 µm to 4.40 µm for Zn-BE respectively. However, machining with Zn-WE yields reduced CD, SR, and increased MRR value and shows less defect on the WEDMed surfaces than its counterpart. The present study developed the mathematical model based on non-linear regression for correlating the machining parameters with the machining responses. The next step of this study is that a unique optimization strategy, namely grey relation analysis (GRA) integrated with Teaching Learning-Based Optimization (TLBO), has been implemented for achieving optimal parametric setting. The satisfactory machining setting obtained from GRA-TLBO has been compared with GRA-JAYA and GRA-genetic algorithm (GA). The proposed methodology appears more fruitful in terms of computational time and effort. |
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ISSN: | 0954-4062 2041-2983 |
DOI: | 10.1177/09544062211023115 |