Prediction and analysis of material removal rate and white layer thickness during wire electrical discharge turning (WEDT) process

George, J and Philip, JT and Mathew, J and Manu, R (2022) Prediction and analysis of material removal rate and white layer thickness during wire electrical discharge turning (WEDT) process. In: CIRP Journal of Manufacturing Science and Technology, 39 . pp. 210-222.

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Abstract

This paper seeks to propose an analytical model for material removal rate (MRR) and white layer thickness (WLT) during wire electrical discharge turning (WEDT) process. This approach considers the predicted crater radius and depth (based on overlapping of craters) for the determination of MRR. The discharge energy (ranging from 4.217 J to 12.228 J) was utilized for the evaluation of the process responses. Besides, a detailed analysis of material removal is visually demonstrated with the aid of a high-speed camera captured at 15,000 fps. The images/videos from the camera help to visualize the material removal process at various discharge energies and input settings. A non-uniform increase in MRR at discharge energy ranging from 4.217 J to 8.475 J was observed, presumably due to the unpredictable wire vibration as confirmed from the high-speed camera. The white layer formation during the process was analyzed using SEM images. Beyond the discharge energy value of 10.276 J (approx.), substantial increase in molten pool formation causes the WLT to shift to a higher incremental slope. The predicted MRR and WLT values are in good agreement with the measured results with an absolute average error of 7.09 and 5.12, respectively. A detailed EDS analysis confirms the variation in surface elemental composition before and after the WEDT process. © 2022 Elsevier Ltd

Item Type:	Journal Article
Publication:	CIRP Journal of Manufacturing Science and Technology
Publisher:	Elsevier Ltd
Additional Information:	The copyright for this article belongs to Elsevier Ltd.
Keywords:	Electric discharge machining; Electric discharges; Wire, Discharge energy; Electrical discharges; High-speed cameras; Material removal; Material removal rate; Prediction and analysis; Process response; Turning process; White layer thickness; Wire electrical discharge turning, High speed cameras
Department/Centre:	Division of Mechanical Sciences > Materials Engineering (formerly Metallurgy)
Date Deposited:	06 Oct 2022 06:28
Last Modified:	06 Oct 2022 06:28
URI:	https://eprints.iisc.ac.in/id/eprint/77136

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