This paper presents, the experimental study has been made to optimize the process parameters during machining of H-13 by wire electrical discharge machining (WEDM) using Taguchi L9 orthogonal array method. Following input process parameters of WEDM [Pulse-On time (TON), Pulse-Off time (TOFF) and Wire Speed rate (WS) and Wire Tension (WT)] were chosen as variables to study the process output in ...

Today's High-Speed Machining (HSM) machine tool combines productivity and part quality. The difficulty inherent in HSM operations lies in understanding the impact of machine tool behaviour on machining time and part quality. Analysis of some of the relevant ISO standards (230-1998, 10791-1998) and a complementary protocol for better understanding HSM technology are presented in the first part o...

Thermal issues are critical when machining Ni-based superalloy components designed for high temperature applications. The low thermal conductivity and extreme strain hardening of this family of materials results in elevated temperatures around the cutting area. This elevated temperature could lead to machining-induced damage such as phase changes and residual stresses, resulting in reduced serv...

Wire electrical discharge machining (WEDM) is a special form of traditional electrical discharge machining in which the electrode is a continuously moving conducting wire. The mechanism of metal removal in wire electrical discharge machining involves the complex erosion effect from electric sparks generated by a pulsating direct current power supply. The sparks generated between two closely spa...

5-Axis milling simulations in CAM software are mainly used to detect collisions between the tool and the part. They are very limited in terms of surface topography investigations to validate machining strategies as well as machining parameters such as chordal deviation, scallop height and tool feed. Z-buffer or N-Buffer machining simulations provide more precise simulations but require long com...

Selection of machining conditions for improved performance characteristics has great importance during wire EDM, because numerous control factors contribute during machining. In the present study an attempt has been made to find the optimal machining conditions for multi performance characteristics simultaneously by applying grey relational analysis using entropy measurement for which Taguchi b...

This paper discusses the preliminary development of a neural network-based process monitor and off-line controller for abrasive flow machining of automotive engine intake manifolds. The process is only observable indirectly, yet the time at which machining achieves the specified air flow rate must be estimated accurately. A neural network model is used to estimate when the process has achieved ...

WEDM is one of the important variants of electrical discharge machining (EDM) which uses the thermal energy generated between the electrodes for machining the electrically conducive materials. This method has been successfully implemented in common materials like aluminum, stainless steel etc., But its application in super alloys like Ti6Al4V is still under investigations. This paper reviews th...

Machining operations of aluminum structural parts are typically carried out under high feeds and high cutting speeds. These cutting conditions exert thermal and mechanical loads on the workpiece, which cause changes in the subsurface material. Residual stresses belong to the machining induced changes and can lead to considerable rejection rates as a consequence of part distortion. Due to the si...

Controlling the process variations on the perimeter of a component to the targeted mean in milling is a huge challenge. Several factors such as spindle speed, feed rate, depth of cut, etc. affects this process variation. In this paper, spindle speed and feed rate are considered. Aluminum alloy 6061 widely used materials in aircraft, automobile and helicopter components is selected for this stud...