Papers by Keyword: Kerf Width

Abstract: Steel alloys made of sheet metal are important materials because of their high strength applications in construction, automobiles, ships, aircraft, and military products. Among the best and fastest non-traditional ways to cut sheet metal these days is laser cutting. Therefore, it's important to comprehend how the parameters of LC affect the quality of the cut. A thorough analysis was provided to find out which LC parameters have the greatest impact on cutting quality as well as how they affect the kerf quality and cut surface. An overview of the benefits of LC over other machining techniques was provided. Furthermore, an explanation of the various laser sources and the laser cutting technique were given. by eliminating each source's spectrum of cut material thicknesses and their benefits. Graphs and formulae provided a detailed illustration of the cutting performance characteristics. Tables and graphs that display the whole classification of the examined papers were used to utilized to arrange the discussion and analysis of the research into such a detailed discussions. It was discovered that Steel alloys are the most commonly used for laser cutting (59%), followed by aluminum alloys (13%) and titanium alloys (12%). While other subjects constitute 16% of research in this field It was also found that The most common parameters utilized as controls are cutting speed (30%), Laser power (23%), Assist gas pressure (21%), Pulse frequency (9%) and Focal position (7%), in general the ideal parameters to achieve low (SR), small (HAZ) width, small (KW) and small (KT) are low (Pu), high (V), medium (P), high (SOD), medium (PF), medium (PW), small (ND), small (T), and N2 as an assist gas.

Abstract: In laser cutting processes, the removal of material is achieved without the application of external force, distinguishing it from traditional machining methods. An additional advantage of laser cutting is the ability to achieve desired surface quality in a single step, eliminating the need for additional finishing processes to smoothen and clean the cutting surface. To ensure the quality of the resulting cuts, a comprehensive understanding of the thermal behavior of the cut parts, influenced by the movement of the laser beam, is essential. The article focuses on the numerical simulation of the laser cutting process of the AISI 304 steel sheets with a thickness of 2 mm to investigate the impact of laser cutting parameters on transient thermal fields and the quality of the resulting cuts. A simulation model was developed and verified through temperature measurements during an experimental laser cutting process using the Bystronic Bysprint 3015 CO₂ Laser Cutting Machine. Numerical simulations in ANSYS software were used to design a working diagram showing the relationship between laser power and cutting kerf width for three different cutting speeds: 2000 mm.min^-1, 4000 mm.min^-1, and 5000 mm.min^-1.

Abstract: Composites are being used since decades and imparting excellent properties comparatively. It may be used in numerous industries because of its light weight and specific strength. Machinability of these materials is a concerned aspect. Conventional and The composites have been machined using unconventional machining techniques. Conventional methods are less suitable than non-conventional quoting the best surface finish and ability to machine complex parts. This article investigates the suitability of thermo-electric process for the machining of composites for higher surface quality and material removal. It includes the study of machining by die sinking, wire cut, powder mixed electric discharge machine in different matrix based composites along with the variation of reinforcement. Electric Discharge Machining (EDM) finds its suitability in machining of different metal matrix composites (MMC) more than the Polymer Matrix Composite (PMC) and Ceramic Matrix Composites (CMC). Variation in input parameters listed as Pulse duration, Voltage, Peak Current and Polarity is studied to obtain the optimum resulting parameters as Material Removal Rate (MRR), Surface Roughness (SR), Electrode Wear Rate (EWR) and Kerf Width. Material removal in PMC is 16% more in parallel fibre direction than with perpendicular. Low electrical conductance and high hardness of CMCs limits the use of EDM while natural ceramics are found more suitable for machining. Gap voltage, pulse on time and current are found most crucial in machining MMCs while quantifying material removal and surface roughness.

Abstract: A study on the dimensional tolerance for CO₂ laser wood cutting is focused on the Meranti (Shorea) wood with the thickness of 19 mm. The results on kerf width for two surfaces which are top surface (K_t) and bottom surface (K_b) are investigated. It is interested to find out the optimum cutting parameters to achieve the smallest variance on top and bottom kerf to improve dimensional quality. Laser power, cutting speed, and gas pressure had been selected as investigate parameters and the cut kerf had been analysed. The investigations revealed that laser power and cutting speed are the significant parameters not only in producing a good surface finish, but also in yielding much narrower kerf with to ensure there will be no dimensional errors of the shore wood products. Besides quality, the laser processing approach has overcome most of the challenges faced by conventional production method.

Abstract: In the present study Spark Plasma Sintering (SPS) technique is used to synthesis of particulate Ceramic Matrix Composites (CMCs). SPS is a type of hot pressing method and in this method, the rate of heating is from 100C to 1000C per minute with high densification. TiB₂ (average size of 14 μm) particles were chosen as matrix and SiC (average size of 1 μm) particles were used as reinforcement. In the first stage of the study, synthesis of CMCs with TiB₂ matrix and SiC reinforcement with varying volume% (0, 5, 10 and 15 vol.%) was carried out using Spark Plasma Sintering furnace available at IIT Madras in 1100°C, 40MPa and 10 min hold of time. But machining of CMCs from conventional machining processes is difficult especially to make complex and precise parts from CMCs. Hence, in the second stage of the work, Wire Electric Discharge Machining (WEDM) studies were carried out on the processed four composites by varying current (2, 3 and 4 A), Pulse on (Ton-30, 60 and 90 μs) and Pulse off time (Toff-5, 10 and 15 μs) as per Taguchi L₉ orthogonal array. WEDM studies revealed that at 4A current, 60μs Ton and 5μs Toff gave maximum material removal rate (MRR) of 2.93 mm³/s, 2.27 mm³/s, 2.71 mm³/s and 0.62 mm³/s for CMC with 0% SiC, 5% SiC, 10% SiC, 15% SiC vol.% reinforcement respectively. To reduce material wastage during machining, kerf width is considered and in which 3A current, 90μs Ton and 5μs Toff gave the least kerf of 0.35 mm, 0.32 mm, 0.33 mm and 0.28 mm for 0% SiC, 5% SiC, 10% SiC, 15% SiC vol.% reinforcement respectively.

Abstract: Wire Cut Electrical Discharge Machining (WEDM) is a non-conventional thermal machining process which is capable of accurately machine alloys having high hardness or part having complex shapes that are very difficult to be machined by the conventional machining processes. The WEDM finds applications in automobiles, aero–space, medical instruments, tool and die industries, etc. The input parameters considered for WEDM are pulse on time, pulse off time, flushing pressure, servo voltage, wire feed rate and wire tension. Performance of WEDM is mainly assessed by output variables such as, material removal rate (MRR), kerf width (Kw) and surface roughness (Ra) of the work piece being machined. Looking at the need of a suitable optimization model, the present work explores the feasibility of machine learning concepts to predict optimum surface roughness and kerf width simultaneously by making use of experimental data available in the literature for machining of Hastelloy C– 276 using WEDM. In most of the literatures, single objective optimization has been carried out for predicting optimum cutting parameters for WEDM. Hence, the present work presents a methodology that makes use of a machine learning algorithm namely, gradient descent method as an optimization technique to optimize both surface roughness and kerf width simultaneously (multi objective optimization) and compare the results with the existing literatures. It was observed that the input parameters such as pulse on time, pulse off time, and peak current have significant effect on both surface roughness and kerf width. The gradient descent method was successfully used for predicting the optimum values of response variables.

Abstract: Wire electrical discharge machining is a material removal process of electrically conductive materials by the thermo-electric source of energy. This kind of machining extensively used in machining of materials with highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using wire electro-discharge machining with brass wire diameter 0.5mm.The objective of this work is to study the influence of three machining parameters namely peak current, pulse off time and wire tension to kerf width followed by suggesting the best operating parameters towards good machining characteristics. A full factorial experimental design was used with variation of peak current, feed rate and wire tension, with results evaluated using analysis of variance techniques (ANOVA). The test array was further extended to allow for the implementation of Response Surface Methodology (RSM) analysis in order to develop first and second order models for the prediction of kerf width response. The results showed that average percentage error between the predicted and experimental value for kerf width models was less than 2%.

Abstract: Wire electrical discharge machining is a material removal process of electrically conductive materials by the thermo-electric source of energy. This kind of machining extensively used in machining of materials with highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using wire electro-discharge machining with brass wire diameter 0.5mm.The objective of this work is to study the influence of three machining parameters namely peak current, pulse off time and wire tension to cutting rate, material removal rate, surface roughness and kerf width followed by suggesting the best operating parameters towards good machining characteristics. A full factorial experimental design was used with variation of peak current, feed rate and wire tension, with results evaluated using analysis of variance techniques. Parameter levels were chosen based on best practice and results from preliminary testing. Main effects plots and percentage contribution ratios are included for the main factors and their interactions.

Abstract: Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L₉ Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (T_ON), pulse-off-time (T_OFF), peak current (I_P), and wire feed (W_F) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.

Abstract: Wire Electrical Discharge Machining (WEDM) is a thermal process that involves melting and vaporisation of work material by a wire electrode in order to obtain the required size. The present work covers a study to improve the material removal rate (MRR) and to machining required slot size by varying frequency lateral vibration of wire while WEDM machining on AISI H13. The machining experiments were conducted by means of two electrode wire materials such as brass and zinc coated wires. The experiments mainly focused on surface integrity aspects like surface/sub surface microstructure, kerf width and surface roughness modification of surfaces machined with Wire Electrical Discharge Machining. The experimental results present the machinability of work material with WEDM process with varying frequency of vibration of wire electrode materials.