Volume 32, Issue 2 (IJIEPR 2021)                   IJIEPR 2021, 32(2): 0-0 | Back to browse issues page

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El-Mahalawy M, SAMUEL M, Fouda N, El-Bahloul S. Investigating the Effect of Wire Electrical Discharge Machining Factors for Ductile Cast Iron (ASTM A536). IJIEPR 2021; 32 (2)
URL: http://ijiepr.iust.ac.ir/article-1-1120-en.html
Investigating the Effect of Wire Electrical Discharge Machining Factors for Ductile Cast Iron (ASTM A536)
Marwa El-Mahalawy1 , M. SAMUEL2 , N. Fouda2 , Sara El-Bahloul 3
1- Higher Future Institute of Engineering & Technology at Mansoura
2- Production & Mechanical Design Engineering Department - Faculty of Engineering - Mansoura University
3- Production & Mechanical Design Engineering Department - Faculty of Engineering - Mansoura University , sara_elbahloul@mans.edu.eg
Abstract:   (2699 Views)
Abstract: Wire Electrical Discharge Machining (WEDM) is a non-traditional thermal machining process used to manufacture irregularly profiled parts. Machining of ductile cast iron (ASTM A536) under several machining factors, which affect the WEDM process, is presented. The considered machining factors are pulse on time (Ton), pulse off (Toff), peak current (Ip), voltage (V), and wire speed (S). To optimize the machining factors, their setting is performed via an experimental design using the Taguchi method. The optimization objective is to achieve maximum Material Removal Rate (MRR) and minimum Surface Roughness (SR). Additionally, the analysis of variance (ANOVA) is used to identify the most significant factor. Also, a regression analysis is carried out to forecast the MRR and SR dependent on defined machining factors. Depending on consequences, the best regulation factors for reaching the maximum MRR are Ton = 32 μs, Toff = 8 μs, Ip = 4 A, S = 40 mm/min. and V = 70 volt. Whereas, the optimal control factors that achieve the minimum SR is Ton = 8 μs, Toff = 8 μs, Ip = 2 A, S = 20 mm/min, and V= 30 volt. It is hypothesized that the perfect combination of control factors that achieves minimum SR and maximum MRR is Ton = 8 μs, Toff = 8 μs, Ip=5 A, S=50 mm/min. The microstructure of the machined surface in the optimal machining conditions shows a very narrow recast layer at the top of the machined surface.
Keywords: Wire electrical discharge machining, Material removal rate, Surface roughness, Taguchi, Analysis of variance, Regression analysis
Full-Text [PDF 857 kb]   (1139 Downloads)    
Type of Study: Research | Subject: Optimization Techniques
Received: 2020/09/25 | Accepted: 2021/06/19 | Published: 2021/06/19
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