Syed Hussain Imran Jaffery

This research is carried out to explore the effect of machining (WEDM) parameters on the corners cutting in D2 tool steel including the determination of optimum input values such as pulse on time, pulse off time, discharge gap, wire speed, and wire tension, for excellent machining performance. In the present study Taguchi technique, which uses L16 orthogonal array is utilized for the design of experiments and optimization, signal-to-noise (S/N) ratio, and main effects plots, analysis is used to identify significant factors and their optimal values according to its level to obtain superior machining characteristics. Five process control parameters, namely, pulse on, pulse off time, discharge gap, wire feed, and wire tension are analyzed for four response parameters viz kerf width, corner error of top and bottom side of the machined profile, and surface roughness. Regression models are developed for all the WEDM responses, and main effects plots and analysis of variance (ANOVA) are used to analyze the notable factors influencing the kerf width, corner error top and bottom sides, and surface roughness. Pulse-on and pulse-off time, discharge gap, and wire speed have been identified as the most influential factors for kerf width, corner error, and surface roughness. It is observed that the predicted values of all the performance measures from regression models are within 95% confidence intervals compared to experimental results of all the response variables, so the predicted regression equations of all response values are useful to estimate the machining performance of WEDM processes. The WEDM machined surface of selected workpieces is analyzed with the help of an optical microscope, and scanning electron microscope (SEM), coupled with energy dispersive X-ray spectroscopy (EDX), elemental composition, resolidified region, micro-cracks, craters, heat-affected zone, and white layer, are observed on the machined surface at different magnification.

Electromagnetic forming is a high-velocity forming process in which repulsive forces between conducting coil and workpiece are generated by mutual inductance, thus, creating opposite magnetic fields and Lorentz forces on conducting bodies. In such processes, the formability can be enhanced owing to the high-speed deformation of the material. This paper presents a fully-coupled numerical model and experimental study of the deformation behaviour of aluminium alloy (AL3014) using closed die magnetic pulse forming. The current density, magnetic flux density and Lorentz force of 1mm thick sheet were estimated numerically. The effect of deforming sheet on magnetic flux and induction was considered. As a result of which the percentage error in sheet deformation reduced from 10% for the existing uncoupled model to 5% for the fully coupled proposed model.

Non-traditional machining processes are popular for generating complex features on the work piece. With advances in material engineering, new ways of cutting technologies has been emerged. However, EDM (Electric Discharge Machining) has gained recognition for producing extraordinary surface finished, intricate part geometries with accuracy and its ability to cut through difficult to machined materials. However, like every product cycle, manufacturing processes also require energy to convert raw materials into finished product. In manufacturing operations, energy input gives carbon footprints which have an effect on our environment. It is observed that reducing energy consumption is becoming the main concern of manufacturers because of enforcing environmental laws and due to the economics of the processing. It is argued that world’s 70% of energy consumption is consumed by manufacturing sector. The aim of the work was to identify direct energy demands in wire cut EDM. The variability in energy demand was explored by operating wire cut EDM at no-load and loaded conditions.Stainless steel S304 was used as a work piece. Experiments were performed on three different wire-cut EDM.Molybdenum wire, brass wire andcopper wire were used as an electrode wire and distilled water was used as a working fluid. During the experiment, electrical current was measured and the variation of power requirement was evaluated. Power required by different features of EDM was compared with the existing energy models and factors were identified that consume most of the electrical energy. Further, a comparison is made between traditional and non-traditional machining processes. This contribution will help to assess energy efficiency of EDM technology and identify priority areas for improvements. This work is also significant for machine tool designers for optimum utilization of energy,reduced environmental impact and reduced production cost of their machine tool.