Journals A-Z
All Subjects
Free Journals
sciepub.com
American Journal of Mechanical Engineering
ISSN (Print): 2328-4102 ISSN (Online): 2328-4110 Website: http://www.sciepub.com/journal/ajme Editor-in-chief: Kambiz Ebrahimi, Dr. SRINIVASA VENKATESHAPPA CHIKKOL
Open Access
Journal Browser
Go
Issue 3, Volume 6
Article Metrics
  • 421
    Views
  • 313
    Saves
  • 0
    Citations
  • 12
    Likes
Export Article
American Journal of Mechanical Engineering. 2018, 6(3), 132-147
DOI: 10.12691/ajme-6-3-6
Open AccessArticle

Experimental Investigation of Wire-EDM Process Parameters for Surface Roughness in the Machining of Carbon Steel 1017 and Aluminum Alloy 6060

Mohammad S. Alsoufi1, and Dhia K. Suker1

1Department of Mechanical Engineering, College of Engineering and Islamic Architecture, Umm Al-Qura University, Makkah, KSA

Pub. Date: November 28, 2018
View Full Text Full Text PDF (722 KB) Full Text ePUB(2147 KB)

Cite this paper:
Mohammad S. Alsoufi and Dhia K. Suker. Experimental Investigation of Wire-EDM Process Parameters for Surface Roughness in the Machining of Carbon Steel 1017 and Aluminum Alloy 6060. American Journal of Mechanical Engineering. 2018; 6(3):132-147. doi: 10.12691/ajme-6-3-6

Abstract

Electrical discharge machining is an old technology that has been used for old manufacturing processes. Nowadays, the modernized version of the machine is used to manufacture different objects using a wire feed. The parameters in which the machine operates have diverse effects on product quality and surface finish. This paper investigates the performance of a wire electrical discharge machining process for different wire feed rates. The process is a non-traditional machining method. Several tests have been performed considering a carbon steel 1017 and aluminum alloy 6060 machined via Wire-EDM. By using different wire feed rates (3 mm/min, 5 mm/min and 7 mm/min), the average surface roughness, Ra, has been investigated in this study. Results show that the wire feed rate is a significant variable to the surface quality finish. The surface roughness of the test target materials increased as this variable increased. The present study recommends setting the wire feed rate as low as possible with the aim of improving results in the surface quality finish. The obtained results and some of the most necessary parameters affecting the manufacturing process of wire-EDM are briefly defined and are then discussed in detail in this study.

Keywords:
Wire-EDM Surface Roughness wire feed rate carbon steel 1017 aluminum alloy 6060

Creative CommonsThis work is licensed under a Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/

Figures

Figure of 10

References:

[1]  Salman, Ö. and M.C. Kayacan, Evolutionary programming method for modeling the EDM parameters for roughness. Journal of Materials Processing Technology, 2008. 200(1): p. 347-355.
 
[2]  Kiyak, M. and O. Çakır, Examination of machining parameters on surface roughness in EDM of tool steel. Journal of Materials Processing Technology, 2007. 191(1): p. 141-144.
 
[3]  Luis, C.J., I. Puertas, and G. Villa, Material removal rate and electrode wear study on the EDM of silicon carbide. Journal of Materials Processing Technology, 2005. 164-165: p. 889-896.
 
[4]  Ho, K.H. and S.T. Newman, State of the art electrical discharge machining (EDM). International Journal of Machine Tools and Manufacture, 2003. 43(13): p. 1287-1300.
 
[5]  Zeilmann, R.P., T. Ivaninski, and C. Webber, Surface integrity of AISI H13 under different pulse time and depths by EDM process. Procedia CIRP, 2018. 71: p. 472-477.
 
[6]  Tilekar, S., S.S. Das, and P.K. Patowari, Process Parameter Optimization of Wire EDM on Aluminum and Mild Steel by Using Taguchi Method. Procedia Materials Science, 2014. 5: p. 2577-2584.
 
[7]  Puertas, I., C.J. Luis, and G. Villa, Spacing roughness parameters study on the EDM of silicon carbide. Journal of Materials Processing Technology, 2005. 164-165: p. 1590-1596.
 
[8]  Puertas, I. and C.J. Luis, A study on the machining parameters optimisation of electrical discharge machining. Journal of Materials Processing Technology, 2003. 143-144: p. 521-526.
 
[9]  Klocke, F., et al., Investigations on Surface Integrity of Heat Treated 42CrMo4 (AISI 4140) Processed by Sinking EDM. Procedia CIRP, 2016. 42: p. 580-585.
 
[10]  Kunieda, M., et al., Advancing EDM through Fundamental Insight into the Process. CIRP Annals, 2005. 54(2): p. 64-87.
 
[11]  Schumacher, B.M., After 60 years of EDM the discharge process remains still disputed. Journal of Materials Processing Technology, 2004. 149(1): p. 376-381.
 
[12]  Yin, Q., et al., Research of lower tool electrode wear in simultaneous EDM and ECM. Journal of Materials Processing Technology, 2014. 214(8): p. 1759-1768.
 
[13]  Garg, R.K., et al., Review of research work in sinking EDM and WEDM on metal matrix composite materials. The International Journal of Advanced Manufacturing Technology, 2010. 50(5): p. 611-624.
 
[14]  Srinivasa Rao, P., K. Ramji, and B. Satyanarayana, Effect of wire EDM conditions on generation of residual stresses in machining of aluminum 2014 T6 alloy. Alexandria Engineering Journal, 2016. 55(2): p. 1077-1084.
 
[15]  Welling, D., Results of Surface Integrity and Fatigue Study of Wire-EDM Compared to Broaching and Grinding for Demanding Jet Engine Components Made of Inconel 718. Procedia CIRP, 2014. 13: p. 339-344.
 
[16]  Bobbili, R., V. Madhu, and A.K. Gogia, An experimental investigation of wire electrical discharge machining of hot-pressed boron carbide. Defence Technology, 2015. 11(4): p. 344-349.
 
[17]  Takayama, Y., et al., The Latest Technology of Wire-cut EDM. Procedia CIRP, 2016. 42: p. 623-626.
 
[18]  Maradia, U., et al., Electrode wear protection mechanism in meso–micro-EDM. Journal of Materials Processing Technology, 2015. 223: p. 22-33.
 
[19]  Fu, X., et al., Surface Roughness Research of Piezoelectric Self adaptive Micro-EDM. Procedia CIRP, 2016. 42: p. 563-568.
 
[20]  Tsai, H.C., B.H. Yan, and F.Y. Huang, EDM performance of Cr/Cu-based composite electrodes. International Journal of Machine Tools and Manufacture, 2003. 43(3): p. 245-252.
 
[21]  2Ramarao, P.V. and M.A. Faruqi, Characteristics of the surfaces obtained in electro-discharge machining. Precision Engineering, 1982. 4(2): p. 111-113.
 
[22]  Wang, C.C., et al., Cutting austempered ductile iron using an EDM sinker. Journal of Materials Processing Technology, 1999. 88(1): p. 83-89.
 
[23]  Lee, S.H. and X.P. Li, Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide. Journal of Materials Processing Technology, 2001. 115(3): p. 344-358.
 
[24]  Halkaci, H.S. and A. Erden. Experimental investigation of surface roughness in electric discharge machining (EDM). in Proceedings of the 6th Biennial Conference on Engineering Systems Design and Analysis. 2002. Istanbul, Turkey: ASME.
 
[25]  Lee, S.H. and X. Li, Study of the surface integrity of the machined workpiece in the EDM of tungsten carbide. Journal of Materials Processing Technology, 2003. 139(1): p. 315-321.
 
[26]  Guu, Y.H., et al., Effect of electrical discharge machining on surface characteristics and machining damage of AISI D2 tool steel. Materials Science and Engineering: A, 2003. 358(1): p. 37-43.
 
[27]  Çoǧun, C., B. Kocabaş, and A. Özgedik, Experimental and theoretical investigation of workpiece surface profiles in electrical discharge machining (EDM) Journal of the Faculty of Engineering and Architecture of Gazi University, 2004. 19(1): p. 97-106.
 
[28]  Keskin, Y., H.S. Halkacı, and M. Kizil, An experimental study for determination of the effects of machining parameters on surface roughness in electrical discharge machining (EDM). The International Journal of Advanced Manufacturing Technology, 2006. 28(11): p. 1118-1121.
 
[29]  Ozgedik, A. and C. Cogun, An experimental investigation of tool wear in electric discharge machining. The International Journal of Advanced Manufacturing Technology, 2006. 27(5): p. 488-500.
 
[30]  Singh, S., S. Maheshwari, and P.C. Pandey, Some investigations into the electric discharge machining of hardened tool steel using different electrode materials. Journal of Materials Processing Technology, 2004. 149(1): p. 272-277.
 
[31]  Singh, S. and A. Bhardwaj, Review to EDM by Using Water and Powder-Mixed Dielectric Fluid. Journal of Minerals and Materials Characterization and Engineering, 2011. 10(2): p. 199-230.
 
[32]  Patel, V.D., et al., Review of Wire-Cut EDM Process on Titanium alloy. International Journal of Engineering Research and Applications 2014. 4(12): p. 112-121.
 
[33]  Dong, W.P., P.J. Sullivan, and K.J. Stout, Comprehensive study of parameters for characterizing three-dimensional surface topography I: Some inherent properties of parameter variation. Wear, 1992. 159(2): p. 161-171.
 
[34]  Dong, W.P., P.J. Sullivan, and K.J. Stout, Comprehensive study of parameters for characterizing three-dimensional surface topography II: Statistical properties of parameter variation. Wear, 1993. 167(1): p. 9-21.
 
[35]  Dong, W.P., P.J. Sullivan, and K.J. Stout, Comprehensive study of parameters for characterizing three-dimensional surface topography III: parameters for characterising amplitude and some functional properties. Wear, 1994. 178(1): p. 29-43.
 
[36]  Dong, W.P., P.J. Sullivan, and K.J. Stout, Comprehensive study of parameters for characterising three-dimensional surface topography: IV: Parameters for characterising spatial and hybrid properties. Wear, 1994. 178(1-2): p. 45-60.
 
[37]  Thomas, T.R., Characterization of surface roughness. Precision Engineering, 1981. 3(2): p. 97-104.
 
[38]  Alsoufi, M.S. and T.M. Bawazeer, Quantifying assessment of touch-feel perception: an investigation using stylus base equipment and self-touch (human fingertip). Umm Al-Qura University: Journal of Engineering and Architecture, 2015. 1(1): p. 1-16.
 
[39]  Alsoufi, M.S. and T.M. Bawazeer, The Effect of Aggressive Biological Materials on a Painted Automotive Body Surface Roughness. American Journal of Nano Research and Applications, 2015. 3(2): p. 17-26.
 
[40]  Suker, D.K., et al., Studying the Effect of Cutting Conditions in Turning Process on Surface Roughness for Different Materials. World Journal of Research and Review (WJRR) 2016 2(4): p. 16-21.
 
[41]  Alsoufi, M.S., et al., Experimental Study of Surface Roughness and Micro-Hardness Obtained by Cutting Carbon Steel with Abrasive WaterJet and Laser Beam Technologies. American Journal of Mechanical Engineering, 2016. 4(5): p. 173-181.
 
[42]  Bawazeer, T.M., et al., Effect of Aqueous Extracts of Salvadora Persica “Miswak” on the Acid Eroded Enamel Surface at Nano-Mechanical Scale. Materials Sciences and Applications, 2016. 7(11): p. 754-771.
 
[43]  Alsoufi, M.S., et al., Surface Roughness and Knoop Indentation Micro-Hardness Behavior of Aluminium Oxide (Al2O3) and Polystyrene (C8H8)n Materials International Journal of Mechanical & Mechatronics Engineering 2016. 16(6): p. 43-49.
 
[44]  Alsoufi, M.S., State-of-the-Art in Abrasive Water Jet Cutting Technology and the Promise for Micro- and Nano-Machining. International Journal of Mechanical Engineering and Applications, 2017. 5(1): p. 1-14.
 
[45]  Alsoufi, M.S., et al., Influence of Abrasive Waterjet Machining Parameters on the Surface Texture Quality of Carrara Marble. Journal of Surface Engineered Materials and Advanced Technology, 2017. 7(2): p. 25-37.
 
[46]  Alsoufi, M.S., et al., Abrasive WaterJet Machining of Thick Carrara Marble: Cutting Performance vs. Profile, Lagging and WaterJet Angle Assessments. Materials Sciences and Applications, 2017. 8(5): p. 361-375.
 
[47]  Alsoufi, M.S., et al., The Effect of Detergents on the Appearance of Automotive Clearcoat Systems Studied in an Outdoor Weathering Test Materials Sciences and Applications, 2017. 8(7): p. 521-536.
 
[48]  Alsoufi, M.S. and A.E. El-Sayed, Warping Deformation of Desktop 3D Printed Parts Manufactured by Open Source Fused Deposition Modeling (FDM) System. International Journal of Mechanical and Mechatronics Engineering, 2017. 17(4): p. 7-16.
 
[49]  Alsoufi, M.S. and A.E. El-Sayed, How Surface Roughness Performance of Printed Parts Manufactured by Desktop FDM 3D Printer with PLA+ is Influenced by Measuring Direction. American Journal of Mechanical Engineering, 2017. 5(5): p. 211-222.
 
[50]  Alsoufi, M.S. and A.E. El-Sayed, Surface Roughness Quality and Dimensional Accuracy - A Comprehensive Analysis of 100% Infill Printed Parts Fabricated by a Personal/Desktop Cost-Effective FDM 3D Printer Materials Sciences and Applications, 2018. 9(1): p. 11-40.
 
[51]  Alsoufi, M.S. and A.E. El-Sayed, Quantitative analysis of 0% infill density surface profile of printed part fabricated by personal FDM 3D printer International Journal of Engineering & Technology, 2018. 7(1): p. 44-52.
 
[52]  ISO4287, Geometrical Product Specifications (GPS) -- Surface texture: Profile method -- Terms, definitions and surface texture parameters. 1997, ISO.
 
[53]  Wang, W., et al., High efficiency slicing of low resistance silicon ingot by wire electrolytic-spark hybrid machining. Journal of Materials Processing Technology, 2009. 209(7): p. 3149-3155.
 
[54]  Punturat, J., V. Tangwarodomnukun, and C. Dumkum, Surface characteristics and damage of monocrystalline silicon induced by wire-EDM. Applied Surface Science, 2014. 320: p. 83-92.
 
Manuscript template