Page 22 - 2021

Ph.D.
(Engineering & Technology)
AN EXPERIMENTAL INVESTIGATION AND PARAMETRIC OPTIMIZATION
USING VARIOUS WIRE ELECTRODES ON DIVERSE INDUSTRIAL
MATERIALS IN WIRE-EDM
Ph.D. Scholar : Patel Vijaykumar Dasharathbhai
Research Supervisor : Dr. Dhaval M. Patel

Regi. No.: 14146051007
Abstract :
Wire Electro Discharge Machining (EDM) is a type of metalworking that uses electrical
corrosion to remove material from a conductive work piece. The purpose of this research
is to determine the optimal Wire-EDM material for manufacturing aerospace and
automotive components. Titanium and SAILMA 350 are primarily employed in the
aerospace and automotive industries, respectively, for the fabrication of airframes and
engine components. Wire feed rate, pulse on time, pulse off time, peak current, and servo
voltage are all considered as input process factors. The performance parameters are
material removal rate (MRR), kerf width, and surface roughness. Additionally, this
experiment makes use of a range of wire types, including half-hard brass wire and zinc-
coated brass wire, in order to determine the optimal wire material for achieving the
optimum reaction. Experiment with various input parameters to determine the influence
each parameter has on performance. Taguchi L18 orthogonal arrays are used to design
material removal rate, kerf width, and surface roughness. ANOVA and the S/N ratio are
used to optimize parameters in order to discover the optimal wire and workpiece
materials for superior performance across a range of metrics, including material removal
rate, Kerf width, and surface roughness. Additionally, as a result of the significant
temperature gradients created at the gap during Wire Electrical Discharge Machining
(WEDM) in a tiny heat-affected zone, the surfaces of Wire Electrical Discharge Machining
parts. The study's findings show the presence of zones with a high temperature gradient
and places with a significant heat flow. A steady-state thermal analysis is used to study
the temperature distribution, assuming a Gaussian heat source with temperature-
dependent material properties. This study demonstrates the use of an axisymmetric
thermophysical finite element model to simulate single spark machining during wire
electrical discharge machining (WEDM). Additionally, a main cut to trim cut strategy is
used for Titanium and SAILMA 350 materials to achieve a high level of surface quality.
This demonstrates that the trim cut strategy is superior to the main cut strategy, and that
the SAILMA 350 material achieves a higher level of surface quality than Titanium.
Additionally, SAILMA 350 is utilized in machining to determine the surface integrity of
discharge energy modes ranging from high to low during main and trim cuts. The
following characteristics of the input process are considered: pulse on time (Ton), pulse

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