Optimization of Surface Roughness Using Multiple-Cut Method in Wire Electrical Discharge Machining

Öz

The trim cut process in wire electrical discharge machining (WEDM) is considered as a possible solution to improve surface properties and geometric accuracy by removing a small amount of chip from the surface obtained after main cut process. In this work, the effects of cutting parameters on the mean surface roughness (Ra), quadratic mean roughness (Rq) and maximum roughness (Rz) criteria formed during the cutting of SAE 1080 carbon steel on the WEDM machine were investigated. Control factors were determined as the machine variables pulse duration (Ton), table feed speed (TS) and pulse interval (Toff). Experiments were performed based on the Taguchi L9 orthogonal sequence. Analysis of variance (ANOVA) was applied to define the impact levels of control factors on the Ra, Rq and Rz roughness criteria. Additionally, parameter optimization was performed using the “smallest is best” approach for main cutting and final cutting applications. Based on the ANOVA outcomes, it was detected that the most influence cutting parameter on the considered surface roughness criteria was the pulse duration in the main cut and trim cut. As a result of the study, it was seen that an average improvement of 21.5%, 10.5% and 12.5% was achieved for Ra, Rq and Rz, respectively, in the trim cut process compared to the main cut process.

Anahtar Kelimeler

• WEDM
• Main cut
• Trim cut
• Surface roughness
• Optimization

Tel Erozyonla Kesmede Çoklu Kesim Yöntemi Kullanılarak Yüzey Pürüzlülüğünün Optimizasyonu

Öz

Tel erozyonla işlemede (WEDM) son kesim işlemi, ana kesim işleminden sonra elde edilen yüzeyden çok az miktarda talaş kaldırarak yüzey özelliklerini ve geometrik doğruluğu iyileştirmek için olası bir çözüm olarak kabul edilmektedir. Bu çalışmada, SAE 1080 karbon çeliğinin tel erozyon tezgâhında kesilmesi sırasında oluşan ortalama yüzey pürüzlülüğü (Ra), kuadratik ortalama pürüzlülük (Rq) ve maksimum pürüzlülük (Rz) kriterlerine kesme parametrelerinin etkileri araştırılmıştır. Kontrol faktörleri, tezgâh değişkenlerinden vurum süresi (Ton), tabla ilerleme hızı (TS) ve vurum bekleme süresi (Toff) olarak belirlenmiştir. Deneyler, Taguchi L9 ortogonal dizisine göre yapılmıştır. Ra, Rq ve Rz pürüzlülük kriterleri üzerinde kontrol faktörlerinin etki düzeylerini belirlemek amacıyla varyans analizi (ANOVA) kullanılmıştır. Ayrıca, ana kesim ve son kesim uygulamaları için “en küçük en iyi” yaklaşımı kullanılarak parametre optimizasyonu yapılmıştır. ANOVA sonuçlarına göre, değerlendirilen yüzey pürüzlülük kriterleri üzerinde en etkin kesme parametresini ana kesim ve son kesimde vurum süresi olduğu belirlenmiştir. Çalışma sonucunda, son kesim işleminin ana kesim işlemine göre Ra, Rq ve Rz için sırasıyla ortalama %21.5, %10.5 ve %12.5’lik bir iyileşme elde edildiği görülmüştür.

Anahtar Kelimeler

• WEDM
• Ana kesim
• Son kesim
• Yüzey pürüzlülüğü
• Optimizasyon

Kaynakça

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