Skip to main content
SpringerLink
Log in

Effect of process parameter on wire cut EDM using RSM method

  • Original Paper
  • Published:
International Journal on Interactive Design and Manufacturing (IJIDeM) Aims and scope Submit manuscript

Abstract

The article aims to estimate the importance of machining parameters for the performance measure material removal rate (MRR) in the Wire Electrical Discharge Machining (WEDM) processing of MONEL 400 K. Wire feed, Time On and Time Off (downtime) have been discovered to be more impactful in deciding the MRR criterion substantially. The significant contribution of relevant input parameters varies according to the objective response behaviour of the parameter. The effect of Time off is the inverse of Pulse on Time, and it leads to the increased MRR as Time off increases, but surface roughness decreases. The material was flushed away effectively during higher Time off, leading to good-quality machined components. It endeavoured to recognize the most significant machining factors for experimentation, and the response surface methodology (RSM) strategy tracks down the best arrangement of boundaries for increasing the MRR. Parametric evaluation on WEDM of MONEL 400 K stands new in this study which many researchers fail to explore in detail followed by response surface methodology to analyse the results. The conformity tests were completed to assess the RSM strategy's expected outcome, proving promising. The results confirmed that the increased MRR of 0.06938 gm/min is obtained at the optimal level of pulse On Time of 10 μs, down Time of 2 μs, and wire feed rate of 4 m/min.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Abbreviations

MRR:

Material removal rate

WEDM:

Wire electrical discharge machining

RSM:

Response surface methodology

S/N:

Signal to noise ratio

ANOVA:

Analysis of variance

EDM:

Electrical discharge machining

KW:

Kerf Width

VIF:

Variance inflation factor

μs:

microseconds

m/min:

metre/min

gm/min:

gram/minute

V:

voltage

A:

Ampere

df:

Degrees of freedom

References

  1. Matanda, B.K., Patel, V., Singh, B., Joshi, U., Joshi, A., Oza, A.D., Kumar, S.: A review on parametric optimization of EDM process for nanocomposites machining: experimental and modelling approach. Int. J. Interact. Design Manuf. (IJIDeM) 1, 10 (2023). https://doi.org/10.1007/s12008-023-01353-1

    Article  Google Scholar 

  2. Vignesh, M., Ramanujam, R.: Machining of Ti–6Al–4V using diffusion annealed zinc-coated brass wire in WEDHT. J. Brazil. Soc. Mech. Sci. Eng. 41(359), 1–10 (2019)

    Google Scholar 

  3. Pain, P., Bose, G.K., Bose, D.: Parametric analysis and optimization of aluminium and SS 204 material using micro-EDM system. Int. J. Interact. Design Manuf. (IJIDeM) (2023). https://doi.org/10.1007/s12008-023-01350-4

    Article  Google Scholar 

  4. Vignesh, M., Ramanujam, R.: Response optimization in wire electrical discharge machining of AISI H11 tool steel using Taguchi – GRA approach. Int. J. Mach. Mach. Mater. 20(5), 474–495 (2018)

    Google Scholar 

  5. Radhika, N., Kishore Chandran, G., Shivaram, P., Vijay Karthik, K.T.: Multi-objective optimization of EDM parameters using Grey Relation Analysis. J. Eng. Sci. Technol. 10(1), 1–11 (2015)

    Google Scholar 

  6. Basil, K., Josephkunju Paul, Jeoju M. Issac,: Spark gap optimization of WEDM process on Ti6Al4V. Int. J. Eng. Sci. Innov. Technol. (IJESIT) 2(1), 364–369 (2013)

    Google Scholar 

  7. Sachdeva, G., Khanna, R., Yadav, P., Nara, A., Singh, N.: Experimental study of H-21 punching dies on wire-cut electric discharge machine using Taguchi’s method. Int. J. Sci. Eng. Res. 4(5), 559–567 (2013)

    Google Scholar 

  8. Shah, C.D., Mevadaand, J.R., Khatri, B.C.: Optimization of process parameter of wire electrical discharge machine by response surface methodology on inconel-600. Int. J. Emerg. Technol. Adv. Eng. 3(4), 2250–2459 (2013)

    Google Scholar 

  9. Hussain, A., Sharma, A.K., Singh, J.P.: Maximizing MRR of Inconel 625 machining through process parameter optimization of EDM. Mater. Today: Proc. 79, 303–307 (2023)

    Google Scholar 

  10. Saravanan, R., Anbuchezhiyan, G., Mamidi, V. K., & Kumaran, P.: Optimizing WEDM parameters on nano-SiC-Gr reinforced aluminum composites using RSM. Adv. Materi. Sci. Eng. 2022, 11 (2022), 1612539. https://doi.org/10.1155/2022/1612539

  11. Tarng, Y.S., Ma, S.C., Chung, L.K.: Determination of optimal cutting parameters in wire electrical discharge machining. Int. J. Mach. Tools Manuf. 35(12), 1693–1701 (1995)

    Article  Google Scholar 

  12. Anbuchezhiyan, G., Mubarak, N.M., Karri, R.R., Abusamin, B., Abnisa, F., Rahman, M.E.: Enriching the microstructure of AZ91D alloy by nano MoO3 composites. J. Alloys Compd. 960, 170613 (2023)

    Article  Google Scholar 

  13. Spedding, T.A., Wang, Z.Q.: Parametric optimization and surface characterization of wire electrical discharge machining process. J. Precis. Eng. 20, 5–15 (1997)

    Article  Google Scholar 

  14. Sarkar, S., Mitra, S., Bhattacharyya, B.: Optimization of wire electrical discharge machining of γ titanium aluminide alloy through an artificial neural network model. Int. J. Adv. Manuf. Technol. 27, 501–508 (2005)

    Article  Google Scholar 

  15. Saleh, M., Anwar, S., El-Tamimi, A., Mohammed, M.K., Ahmad, S.: Milling microchannels in monel 400 alloy by wire EDM: an experimental analysis. Micromachines 11(5), 469 (2020)

    Article  Google Scholar 

  16. Anbuchezhiyan, G., Muthuramalingam, T., Mohan, B.: Effect of process parameters on mechanical properties of hollow glass microsphere reinforced magnesium alloy syntactic foams under vacuum die casting. Archiv. Civ. Mech. Eng. 18, 1645–1650 (2018)

    Article  Google Scholar 

  17. Chalisgaonkar, R., Kumar, J.: Optimization of WEDM process of pure titanium with multiple performance characteristics using Taguchi’s DOE approach and utility concept. Front. Mech. Eng. 8, 201–214 (2013)

    Article  Google Scholar 

  18. Arun Kumar, N.E., Suresh Babu, A., Sathishkumar, N., Pradeep Kumar, C.: Influence of near-dry ambiance on WEDM of Monel superalloy. Mater. Manuf. Process. 36(7), 827–835 (2021)

    Article  Google Scholar 

  19. Karthikeyan, A.G., Kalaiselvan, K., Muralidharan, N.: CNC wire-cut EDM input variables analysis on Ni -based superalloy (MONEL K-500). Mater. Manuf. Process. 37(9), 1035–1044 (2022)

    Article  Google Scholar 

  20. Anbuchezhiyan, G., Saravanan, R., Pugazhenthi, R., Palani, K., & Mamidi, V. K. (2022). Influence of Coated Electrode in Nanopowder Mixed EDM of Al–Zn–Mg–Si 3 N 4 Composite. Advances in Materials Science and Engineering, 2022.

  21. Chen, H.C., Lin, J.C., Yang, Y.K., Tsai, C.H.: Optimization of wire electrical discharge machining for pure tungsten using a neural network integrated simulated annealing algorithm. Expert Syst. Appl. 37, 7147–7153 (2010)

    Article  Google Scholar 

  22. Manikandan, N., Ramesh Raju, K.L., Narasimhamu, A.K. Damodaram.: Optimization of wire electrical discharge machining of Monel 400 using Taguchi-Grey approach. Mater. Today: Proc. 68(5), 1690–1696 (2022)

    Google Scholar 

  23. Anbuchezhiyan, G., Mubarak, N.M., Karri, R.R., Khalid, M.: A synergistic effect on enriching the Mg–Al–Zn alloy-based hybrid composite properties. Sci. Rep. 12(1), 20053 (2022)

    Article  Google Scholar 

  24. NE Arunkumar, A Suresh babu, M Subramanian, and C Pradeep kumar: Influence of wire-EDM parameters on surface characteristics of superalloy monel 400. Surf. Rev. Lett. 29(03), 2250031 (2022)

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, St. Joseph’s College of Engineering, Chennai, 600119, India

    R. Selvam

  2. Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Chennai, TamilNadu, 601103, India

    M. Vignesh

  3. Vels Institute of Science, Technology & Advanced Studies (VISTAS), Chennai, Tamil Nadu, 600117, India

    R. Pugazhenthi

  4. Department of Mechanical Engineering, Saveetha school of Engineering, Chennai, Tamil Nadu, 602105, India

    G. Anbuchezhiyan

  5. Department of Aeronautical Engineering, MLR Institute of Technology, Hyderabad, Telangana, 500043, India

    M. Satyanarayana Gupta

Authors
  1. R. Selvam
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. M. Vignesh
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. R. Pugazhenthi
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. G. Anbuchezhiyan
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. M. Satyanarayana Gupta
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Conceptualization& Methodology: RS. Formal analysis and investigation: RP. Writing - original draft preparation: GA. Writing - review and editing: MV. Supervision: MSG

Corresponding author

Correspondence to G. Anbuchezhiyan.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Selvam, R., Vignesh, M., Pugazhenthi, R. et al. Effect of process parameter on wire cut EDM using RSM method. Int J Interact Des Manuf (2023). https://doi.org/10.1007/s12008-023-01391-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s12008-023-01391-9

Keywords

Search

Navigation