Al 7075 T6 havacılık alaşımının WEDM ile kesme performansının RSM tabanlı araştırılması

Yıl 2024, , 283 - 300, 31.08.2024

Levent Uğur , Kutay Aydın , Hakan Kazan

https://doi.org/10.54365/adyumbd.1465339

Öz

Wire electrical discharge machining (WEDM), havacılık, kalıp ve kalıp yapımı, otomobil endüstrileri ve biyomedikal alanda karmaşık ve zorlu şekillerdeki iletken malzemelerin işlenmesi için yaygın olarak kullanılan bir işleme yöntemdir. WEDM Ürün kalitesinden ödün vermeden güç tüketimini en aza indirmek için üretim sektöründe önemli bir yere sahiptir. Bu doğrultuda, mevcut araştırma, WEDM parametrelerinin sürdürülebilirlik için yüzey pürüzlülüğü, kerf genişliği ve çevresel kaygı için güç tüketimi güç tüketimi ile ilişkisi Response Surface Methodology (RSM) ile araştırılmıştır. Deneysel araştırmalar için, 0,18 mm Guangming Molibden alaşım tel kullanılarak Feed rate, pulse width, pulse space ve wire speed gibi işleme parametreleri seçilmiştir. RSM, deneyleri tasarlamak ve yüzey pürüzlülüğünü, güç tüketimini ve kerf genişliğini en aza indirmek için WEDM'nin bağımsız parametrelerini analiz etmek ve optimize etmek için kullanılmıştır. Deneyler sonucunda optimum üretim parametreleri belirlendi. Varyans analizinden (ANOVA) önemli proses parametreleri belirlendi. Ayrıca, optimum proses parametrelerinin performansını doğrulamak için doğrulama deneyi yapılmış ve deneysel değerlerle iyi bir uyum içinde olduğu kaydedilmiştir. Sonuç olarak, yüzey pürüzlülüğü, kesme gücü ve kerf genişliği üzerindeki en etkin parametreler sırasıyla %67,96 oranla pulse width, 54,96 oranla wire speed, %63,65 oranla pulse width olduğu anlaşılmıştır.

Anahtar Kelimeler

Tel erozyon yöntemi, WEDM, Al 7075 T6, Yüzey pürüzlülüğü, Kesme gücü, Kerf genişliği

Etik Beyan

-

Destekleyen Kurum

-

Proje Numarası

-

Teşekkür

-

RSM-based measurement of cutting performance on Al 7075 T6 aero-structural alloy using WEDM

Öz

Wire electrical discharge machining (WEDM) is a machining method commonly used in the aerospace, die making, automotive, and biomedical fields for machining complex and challenging shapes of conductive materials. WEDM is used in manufacturing to reduce power consumption while maintaining product quality. The current study used Response Surface Methodology (RSM) to investigate the relationship of WEDM parameters with surface roughness, kerf width, and power consumption for environmental concerns. Cutting parameters such as feed rate, pulse width, pulse space, and wire speed were chosen for experimental studies using 0.18 mm Guangming Molybdenum alloy wire. RSM was used to design experiments, analyze, and optimize WEDM independent parameters to minimize surface roughness, power consumption, and kerf width. The experiments yielded optimal cutting parameters. Analysis of variance (ANOVA) was used to determine important cutting parameters. Furthermore, a validation experiment was carried out to verify the performance of the optimum cutting parameters, which were found to be in good agreement with the experimental values. As a result, the most effective parameters for surface roughness, cutting power, and kerf width were discovered to be pulse width (67.96%), wire speed (54.96%), and pulse width (63.65%), respectively.

Anahtar Kelimeler

Wire cutting method, WEDM, Al 7075 T6, Surface roughness, Cutting power, Kerf width

Etik Beyan

-

Destekleyen Kurum

-

Proje Numarası

-

Teşekkür

-

Kaynakça

• Feng, L, Che, Y, Liu, Y, Qiang, X, and Wang, Y. Fabrication of superhydrophobic aluminium alloy surface with excellent corrosion resistance by a facile and environment-friendly method. Applied Surface Science. 2013;283:367-374.
• Zuo, M, Sokoluk, M, Cao, C, Yuan, J, Zheng, S, and Li, X. Microstructure control and performance evolution of aluminum alloy 7075 by nano-treating. Scientific reports. 2019;9(1):1-11.
• Attahu, CY, An, L, Li, Z, and Gao, G. Influence of shim layers on progressive failure of a composite component in composite-aluminum bolted joint in aerospace structural assembly. Transactions of Nanjing University of Aeronautics and Astronautics. 2018;35(1):188-202.
• Yang, Y, Li, M, and Li, K. Comparison and analysis of main effect elements of machining distortion for aluminum alloy and titanium alloy aircraft monolithic component. The International Journal of Advanced Manufacturing Technology. 2014;70(9):1803-1811.
• Singh, AK, Singhal, D, and Kumar, R. Machining of aluminum 7075 alloy using EDM process: An ANN validation. Materials Today: Proceedings. 2020;26:2839-2844.
• Sharma, P, Chakradhar, D, and Narendranath, S. Measurement of WEDM performance characteristics of aero-engine alloy using RSM-based TLBO algorithm. Measurement. 2021;179:109483.
• Dewan, P, Kundu, P, and Phipon, R. Powder mixed electric discharge machining–A review. AIP Conference Proceedings. AIP Publishing, 2020.
• Dewan, PR and Kundu, PK. On Titanium Powder Mixed Electric Discharge Machining of Nimonic C-263. Journal of The Institution of Engineers (India): Series D. 2022:1-8.
• Dewan, PR and Kundu, PK. Optimizing process parameters for EDM of nimonic C-263 under green dielectric. Sādhanā. 2023;48(4):230.
• Goyal, A and Ur Rahman, H. Experimental studies on Wire EDM for surface roughness and kerf width for shape memory alloy. Sādhanā. 2021;46(3):160.
• Das, S and Joshi, SN. Measurement and analysis of molybdenum wire erosion and deformation during wire electric discharge machining of Ti-6Al-4V alloy. Measurement. 2021;179:109440.
• Kanlayasiri, K and Boonmung, S. Effects of wire-EDM machining variables on surface roughness of newly developed DC 53 die steel: Design of experiments and regression model. Journal of materials processing technology. 2007;192:459-464.
• Zheng, J, Lai, X, Chen, A, and Zheng, W. Energy modeling and minimizing energy consumption control strategy of wire electrical discharge machining (WEDM) through electrical parameters. The International Journal of Advanced Manufacturing Technology. 2019;103(9):4341-4353.
• Shastri, RK and Mohanty, CP. Sustainable electrical discharge machining of Nimonic C263 superalloy. Arabian Journal for Science and Engineering. 2021;46(8):7273-7293.
• Bobbili, R, Madhu, V, and Gogia, A. Modelling and analysis of material removal rate and surface roughness in wire-cut EDM of armour materials. Engineering Science and Technology, an International Journal. 2015;18(4):664-668.
• Kumar, SS, Uthayakumar, M, Kumaran, ST, Parameswaran, P, Mohandas, E, Kempulraj, G, Babu, BR, and Natarajan, S. Parametric optimization of wire electrical discharge machining on aluminium based composites through grey relational analysis. Journal of Manufacturing Processes. 2015;20:33-39.
• Karabulut, Ş, Kökçan, R, Bilgin, M, and Özdemir, A. Study on the Wire Electrical Discharge Machining of AA 7075 Aluminum Alloy. 2018 9th International Conference on Mechanical and Aerospace Engineering (ICMAE). IEEE, 2018.
• Biswas, MS, Mandal, K, and Sarkar, S. MOGA approach in WEDM of advanced aluminium alloy. Materials Today: Proceedings. 2020;26:887-890.
• Jayachandran, S, Raman, M, and Ramasamy, T. Experimental investigation for the optimization of the WEDM process parameters to obtain the minimum surface roughness of the Al 7075 aluminium alloy employed with a zinc-coated wire using RSM and GA. Materiali in Tehnologije. 2019;53(3):349-356.
• Aydın, K, Uğur, L, Güvercin, S, and Gül, F. Investigation of the machining performance of ferritic ductile cast Iron in WEDM using response surface methodology. Sigma Journal of Engineering and Natural Sciences. 2022;40(1):95-107.
• Zhang, Z, Yu, H, Zhang, Y, Yang, K, Li, W, Chen, Z, and Zhang, G. Analysis and optimization of process energy consumption and environmental impact in electrical discharge machining of titanium superalloys. Journal of Cleaner Production. 2018;198:833-846.
• Sharma, N, Khanna, R, and Gupta, R. Multi quality characteristics of WEDM process parameters with RSM. Procedia Engineering. 2013;64:710-719.
• Anderson-Cook, CM, Borror, CM, and Montgomery, DC. Response surface design evaluation and comparison. Journal of Statistical Planning and Inference. 2009;139(2):629-641.
• Shandilya, P, Jain, P, and Jain, N. RSM and ANN modeling approaches for predicting average cutting speed during WEDM of SiCp/6061 Al MMC. Procedia Engineering. 2013;64:767-774.
• Box, GE and Hunter, JS. Multi-factor experimental designs for exploring response surfaces. The Annals of Mathematical Statistics. 1957:195-241.
• Murat, D, Ensarioğlu, C, Gürsakal, N, Oral, A, and Çakır, MC. Evaluation of tool wear for hard turning operations through response surface methodology. 2018.
• Gunaraj, V and Murugan, N. Application of response surface methodology for predicting weld bead quality in submerged arc welding of pipes. Journal of materials processing technology. 1999;88(1-3):266-275.
• Montgomery, DC. Design and analysis of experiments: John wiley & sons; 2017.
• Raj, A, Misra, J, Khanduja, D, Saxena, K, and Malik, V. Design, modeling and parametric optimization of WEDM of Inconel 690 using RSM-GRA approach. International Journal on Interactive Design and Manufacturing (IJIDeM). 2022:1-11.
• Ishfaq, K, Anwar, S, Ali, MA, Raza, MH, Farooq, MU, Ahmad, S, Pruncu, CI, Saleh, M, and Salah, B. Optimization of WEDM for precise machining of novel developed Al6061-7.5% SiC squeeze-casted composite. The International Journal of Advanced Manufacturing Technology. 2020;111:2031-2049.
• Dzionk, S and Siemiątkowski, MS. Studying the effect of working conditions on WEDM machining performance of super alloy Inconel 617. Machines. 2020;8(3):54.
• Anderson, MJ and Whitcomb, PJ. RSM simplified: optimizing processes using response surface methods for design of experiments: Productivity press; 2016.
• Altın Karataş, M. Inconel 718'in tel erozyon ile işlenmesinde yüzey pürüzlülüğünün Taguchi tabanlı gri ilişkisel analiz yöntemi ile çok kriterli optimizasyonu. Pamukkale Üniversitesi Mühendislik Bilimleri Dergisi. 2022;28(4):516-532.
• Dobes, J, Leal, JES, Profeta, J, de Sousa, MM, Neto, FPL, Piratelli-Filho, A, and Arencibia, RV. Effect of mechanical vibration on Ra, Rq, Rz, and Rt roughness parameters. The International Journal of Advanced Manufacturing Technology. 2017;92(1):393-406.
• Azam, M, Jahanzaib, M, Abbasi, JA, and Wasim, A. Modeling of cutting speed (CS) for HSLA steel in wire electrical discharge machining (WEDM) using moly wire. Journal of the Chinese Institute of Engineers. 2016;39(7):802-808.
• Gajjar, DH and Desai, JV. Optimization of MRR, Surface Roughness and KERF Width in wire EDM Using Molybdenum Wire. International Journal for Research in Education. 2015;4(2).
• Soota, T and Rajput, S. Optimization and measurement of kerf width and surface roughness of AISI 316L. Forces in Mechanics. 2022;6:100071.
• Çaydaş, U and Hasçalık, A. Tel Erozyon Yönteminde İşleme Parametrelerinin Alüminyum Alaşımının Yüzey Yapısına Etkisi. Politeknik Dergisi. 2004;7(1):31-36.
• Bolar, G, Das, A, and Joshi, SN. Measurement and analysis of cutting force and product surface quality during end-milling of thin-wall components. Measurement. 2018;121:190-204.
• Kaçal, A and Yıldırım, F. PMD23 Çeliğinin Tornalanmasında CBN Kesici Uçların Kesme Performansının Yüzey Pürüzlülüğü ve Takım Aşınması Üzerindeki Etkilerinin Belirlenmesi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi. 2016;31(1).
• Asiltürk, I, Neşeli, S, and Ince, MA. Optimisation of parameters affecting surface roughness of Co28Cr6Mo medical material during CNC lathe machining by using the Taguchi and RSM methods. Measurement. 2016;78:120-128.
• Goswami, A and Kumar, J. Optimization in wire-cut EDM of Nimonic-80A using Taguchi's approach and utility concept. Engineering Science and Technology, an International Journal. 2014;17(4):236-246.
• Tosun, N, Cogun, C, and Tosun, G. A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method. Journal of materials processing technology. 2004;152(3):316-322.
• Koklu, U. Optimization of Kerf and Surface Roughness of AL 7 475-T 7 351 Alloy Machined with WEDM Process Using The Grey-Based Taguchi Method. Metalurgija/Metallurgy. 2012;51(1):47-50.