Dereje Teshome, Palani Sivaprakasam, Desta Melaku, Čep Robert
Department of Mechanical Engineering, College of Engineering, Addis Ababa Science and Technology University, Addis Ababa P.O. Box 16417, Ethiopia.
Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 708 00 Ostrava, Czech Republic.
Materials (Basel). 2023 Aug 3;16(15):5440. doi: 10.3390/ma16155440.
Nimonic alloy is difficult to machine using traditional metal cutting techniques because of the high cutting forces required, poor surface integrity, and tool wear. Wire electrical discharge machining (WEDM) is used in a number of sectors to precisely machine complex forms of nickel-based alloy in order to attempt to overcome these challenges and provide high-quality products. The Taguchi-based design of experiments is utilized in this study to conduct the tests and analyses. The gap voltage (GV), pulse-on time (Ton), pulse-off time (Toff), and wire feed (WF), are considered as the variable process factors. GRA is used for the WEDM process optimization for the Nimonic-263 superalloy, which has multiple performance qualities including the material removal rate (MRR), surface roughness (SR), and kerf width (KW). ANOVA analysis was conducted to determine the factors' importance and influence on the output variables. Multi objective optimization techniques were employed for assessing the machining performances of WEDM using GRA. The ideal input parameter combinations were determined to be a gap voltage (GV) of 40 V, a pulse-on time (Ton) of 8 µs, a pulse-off time (Toff) of 16 µs, and a wire feed (WF) of 4 m/min. A material removal rate of 8.238 mm/min, surface roughness of 2.83 µm, and kerf width of 0.343 mm were obtained. The validation experiments conducted also demonstrated that the predicted and experimental values could accurately forecast the responses.
由于所需的切削力高、表面完整性差以及刀具磨损，使用传统金属切削技术加工尼莫尼克合金很困难。电火花线切割加工（WEDM）在许多领域被用于精确加工复杂形状的镍基合金，以试图克服这些挑战并提供高质量产品。本研究利用基于田口方法的实验设计进行测试和分析。间隙电压（GV）、脉冲导通时间（Ton）、脉冲关断时间（Toff）和线速度（WF）被视为可变工艺因素。灰色关联分析（GRA）用于尼莫尼克263高温合金的电火花线切割加工工艺优化，该合金具有包括材料去除率（MRR）、表面粗糙度（SR）和切口宽度（KW）在内的多种性能指标。进行方差分析（ANOVA）以确定各因素对输出变量的重要性和影响。采用多目标优化技术，利用灰色关联分析评估电火花线切割加工的性能。确定的理想输入参数组合为：间隙电压（GV）40V、脉冲导通时间（Ton）8µs、脉冲关断时间（Toff）16µs和线速度（WF）4m/min。获得了8.238mm/min的材料去除率、2.83µm的表面粗糙度和0.343mm的切口宽度。所进行的验证实验还表明，预测值和实验值能够准确预测响应结果。
