Optimization On Material Removal Rate And Surface Roughness Of Stainless Steel 304 Wire Mesh Cut Wedm By Topsis Methodology

Abstract

Wire electrical discharge machining (WEDM) is an important technology, which demands high-speed cutting and high-precision machining to realize productivity and improved accuracy for automotive, manufacturing of press stamping dies, prototype parts etc. In
this present work, investigations of cutting performance with pulse on time, pulse off time, servo voltage, wire feed, current and cutting speed were experimentally investigated in wire electric discharge machining (WEDM) process.The EDM wire research currently focuses on achieving higher machining speed and surface integrity. In this regard, US patent 20100012628A1 presents a hybrid wire embedded with electrically nonconducting abrasives This investigation involves using Glass (G), Kevlar(k), and carbon (C) fibres in the Hybrid Synthetic Fibre Polymer (HSGKC) composites for different applications. Synthetic Fibre WireMesh Composite (SFWMC) plates were fabricated using woven G/K/C along with Stainless Steel Wire Mesh (SSWM),. The samples were fabricated using hand-layup and through compression moulding techniques. The Experimental trial-I samples were prepared with G/K, K/G, C/G and G/K/C combinations along with LY556 and HY951. In trial-II the samples were prepared by adding BaSO4 in various weight ratios (1%, 3%, 5% and 7 %). The optimum results were obtained for sample with 5% of BaSO4 addition, and hence the samples uses in the first trial
combinations with 5% of BaSO4were preferred for trial-III. Finally, along with 5% of BaSO4 the experimental trial-IV samples were fabricated using stainless steel, aluminium wire mesh. This results in a remarkable improvement in removal rate and ensures better
recast surface layer when compared to an equivalent WEDM process. Moreover, the need for advanced machining techniques like AWJM is inevitable to produce complex components in the field of automobiles. A study of the (SFWMC) composite was made with special reference to the TOPSIS method for optimizing the cutting parameters of WEDM while minimizing the surface roughness. Each trial was led at varied stand-off distance (D),transverse speed (S), and degrees of water jet pressure (P). For this study, the Material
Removal Rate (MRR), Kerf Taper Angle (KTA), and surface roughness (Ra) were taken as multi criteria characteristics. There was negligible recast material present on the machined surfaces. A majority of this process is dedicated to machining steel. The cutting
performance outputs considered in this study are material removal rate (MRR) and surface roughness. Experimentation has been completed by using Taguchis L16 orthogonal array under different conditions of parameters. The aim of the present investigation is to develop the selection of an optimal combination of WEDM parameters for proper machining of SS 304 to achieve better surface roughness and Materials Removal Rate (MRR). However, it may be useful in machining (such as polycrystalline diamond), which are usually hard to process with WEDM. The abrasion can negatively affect the machining performance, which makes such a process suitable for roughing sequences. Therefore, it is usually developed in a twin-wire machine tool. Although diamond wire can be effective in such work, wire with aluminium oxide abrasives can provide better performance at a lower cost.