A Modeling Study on Surface Roughness of Spinneret Mold Sections Machined By WEDM

Year 2019, Volume: 23 Issue: 1, 85 - 93, 01.02.2019

Erdoğan Kanca Volkan Cem Taşkın Ali Günen

https://doi.org/10.16984/saufenbilder.428457

Abstract

 The wire electrical discharge machining
(WEDM) is widely used in the cutting of Bulk Continuous Filament (BCF)
spinneret molds. Because of the low surface roughness of the spinneret molds
obtained by the WEDM method, it ensures that the polypropylene material has a
steady flow, volume and cross-sectional shape. Since the yarn extruded from the
sections on the BCF acquire a number of physical and visual properties surface
roughness of these molds have a great of importance. In this context, a new
model was developed to predict the surface quality of spinneret mold sections
machined using WEDM by Analysis of variance. Machining parameters such as
voltage, current, pulse time and wire feed rate were used as independent input
variables and surface roughness was used as dependent output parameters.  Contribution of input variables into the
output variable determined by means of analysis of variance (ANOVA). Developed
mathematical model estimations have been found to be in good agreement with the
measured ones. The parameters with the most effect on surface roughness are
listed as voltage, current, pulse, and feed, respectively.

Keywords

WEDM, Surface Quality, ANOVA

References

• REFERENCES [1] S. Kalpakjian, S. Schmid, ''Manufacturing, Engineering and Technology'', 5 ed., Prentice Hall, 2005.
• [2] K.H. Ho, S.T. Newman, S. Rahimifard, R.D. Allen, ''State of the Art in Wire Electrical Discharge Machining (WEDM)'', International Journal of Machine Tools and Manufacture, vol. 44, pp. 1247-1259. DOI: 10.1016/j.ijmachtools, 2004.
• [3] H. Abyar Firouzabadi, J. Parvizian, A. Abdullah, ''Improving Accuracy of Curved Corners in Wire EDM Successive Cutting'', Int. J. Adv Manuf. Technol, 76, 447-459. DOI: 10.1007/s00170-014-6270-0 , 2015.
• [4] J.A. Sanchez, J.L. Rodil, A. Herrero, L.N.L. de Lacalle, A. Lamikiz, ''On the Influence of Cutting Speed Limitation on the Accuracy of Wire-EDM Corner-Cutting'', Journal of Materials Processing Technology, 182, 574-579. DOI: 10.1016/j.jmatprotec.2006.09.030, 2007.
• [5] Z. Chen, Y. Huang, Z. Zhang, H. Li, W. Ming, G. Zhang, ''An Analysis and Optimization of the Geometrical Inaccuracy in WEDM Rough Corner Cutting'', Int. J. Adv. Manuf. Technol., 74, 917-929. DOI: 10.1007/s00170-014-6002-5, 2014.
• [6] M. Durairaj, D. Sudharsun, N. Swamynathan, ''Analysis of Process Parameters in Wire EDM with Stainless Steel Using Single Objective Taguchi Method and Multi Objective Grey Relational Grade'', Procedia Engineering, 64, 868-877. DOI: 10.1016/j.proeng.2013.09.163, 2013.
• [7] V. Aggarwal, S. Khangura, R.K. Garg, ''Parametric Modeling and Optimization for Wire Electrical Discharge Machining of Inconel 718 Using Response Surface Methodology'', Int. J. Adv. Manuf. Technol., 79, 31-47. DOI: 10.1007/s00170-015-6797-8, 2015.
• [8] A. Ramamurthy, R. Sivaramakrishnan, T. Muthuramalingam, ''Taguchi-Grey Computation Methodology for Optimum Multiple Performance Measures on Machining Titanium Alloy in WEDM Process'', Indian Journal of Engineering and Materials Sciences (IJEMS), 22, pp. 181-186, 2015.
• [9] A. Rutherford, ''Introducing Anova and Ancova A Glm Approach'', SAGE Publications, 2001.
• [10] D. Yip-Hoi and D. Dutta, “A genetic algorithm application for sequencing operations in process planning for parallel machining,” IIE Transactions (Institute of Industrial Engineers), vol. 28, no. 1, pp. 55–68, 1996.