Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire

Mudassar Rehman; Sarmad Ali Khan; Rakhshanda Naveed

doi:10.1007/s12206-020-0609-2

Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire

Mudassar Rehman^*
, Sarmad Ali Khan
, Rakhshanda Naveed

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

30 Scopus citations

Abstract

DC53 is considered as superior steel grade by die and mold making industries as compared to D2 and D3 steel due to its excellent mechanical characteristics like high hardness, wear resistance and strength. DC53 steel finds applications in making stamping dies, punches and cutting tools. In wire electric discharge machining (WEDM) process, gamma phase coated wire offers superior machining performance over uncoated brass and zinc coated electrode wires. This work was performed to study the effect of machining variables like sparks on duration, sparks off duration, arc-on time, and servo voltage on response variables, namely kerf width (KW), cutting speed (CS), material removal rate (MRR), and surface roughness (R_a) for WEDM of DC53 steel. Taguchi L18 orthogonal array was used for experimental design. Analysis of variance showed that sparks on duration is the most significant factor affecting KW, CS, and MRR with percentage contribution of 48.25 %, 80.21 %, and 45.21 %, respectively. Optimal set of machining parameters resulted in 14.02 % improvement in MRR and 19.24 % reduction in workpiece surface roughness. Moreover, gamma phase coated wire was found to have 30–35 % faster cutting rate as compared to uncoated brass wire.

Original language	English
Pages (from-to)	2767-2773
Number of pages	7
Journal	Journal of Mechanical Science and Technology
Volume	34
Issue number	7
DOIs	https://doi.org/10.1007/s12206-020-0609-2
State	Published - 1 Jul 2020
Externally published	Yes

Bibliographical note

Publisher Copyright:
© 2020, The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure

Keywords

Analysis of variance
Cutting speed
DC53 die steel
Gamma phase wire electrode
Signal to noise ratio

ASJC Scopus subject areas

Mechanics of Materials
Mechanical Engineering

Access to Document

10.1007/s12206-020-0609-2

Cite this

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title = "Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire",

abstract = "DC53 is considered as superior steel grade by die and mold making industries as compared to D2 and D3 steel due to its excellent mechanical characteristics like high hardness, wear resistance and strength. DC53 steel finds applications in making stamping dies, punches and cutting tools. In wire electric discharge machining (WEDM) process, gamma phase coated wire offers superior machining performance over uncoated brass and zinc coated electrode wires. This work was performed to study the effect of machining variables like sparks on duration, sparks off duration, arc-on time, and servo voltage on response variables, namely kerf width (KW), cutting speed (CS), material removal rate (MRR), and surface roughness (Ra) for WEDM of DC53 steel. Taguchi L18 orthogonal array was used for experimental design. Analysis of variance showed that sparks on duration is the most significant factor affecting KW, CS, and MRR with percentage contribution of 48.25 \%, 80.21 \%, and 45.21 \%, respectively. Optimal set of machining parameters resulted in 14.02 \% improvement in MRR and 19.24 \% reduction in workpiece surface roughness. Moreover, gamma phase coated wire was found to have 30{\textendash}35 \% faster cutting rate as compared to uncoated brass wire.",

keywords = "Analysis of variance, Cutting speed, DC53 die steel, Gamma phase wire electrode, Signal to noise ratio",

author = "Mudassar Rehman and Khan, \{Sarmad Ali\} and Rakhshanda Naveed",

note = "Publisher Copyright: {\textcopyright} 2020, The Korean Society of Mechanical Engineers and Springer-Verlag GmbH Germany, part of Springer Nature.",

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doi = "10.1007/s12206-020-0609-2",

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AU - Rehman, Mudassar

AU - Khan, Sarmad Ali

AU - Naveed, Rakhshanda

PY - 2020/7/1

Y1 - 2020/7/1

N2 - DC53 is considered as superior steel grade by die and mold making industries as compared to D2 and D3 steel due to its excellent mechanical characteristics like high hardness, wear resistance and strength. DC53 steel finds applications in making stamping dies, punches and cutting tools. In wire electric discharge machining (WEDM) process, gamma phase coated wire offers superior machining performance over uncoated brass and zinc coated electrode wires. This work was performed to study the effect of machining variables like sparks on duration, sparks off duration, arc-on time, and servo voltage on response variables, namely kerf width (KW), cutting speed (CS), material removal rate (MRR), and surface roughness (Ra) for WEDM of DC53 steel. Taguchi L18 orthogonal array was used for experimental design. Analysis of variance showed that sparks on duration is the most significant factor affecting KW, CS, and MRR with percentage contribution of 48.25 %, 80.21 %, and 45.21 %, respectively. Optimal set of machining parameters resulted in 14.02 % improvement in MRR and 19.24 % reduction in workpiece surface roughness. Moreover, gamma phase coated wire was found to have 30–35 % faster cutting rate as compared to uncoated brass wire.

AB - DC53 is considered as superior steel grade by die and mold making industries as compared to D2 and D3 steel due to its excellent mechanical characteristics like high hardness, wear resistance and strength. DC53 steel finds applications in making stamping dies, punches and cutting tools. In wire electric discharge machining (WEDM) process, gamma phase coated wire offers superior machining performance over uncoated brass and zinc coated electrode wires. This work was performed to study the effect of machining variables like sparks on duration, sparks off duration, arc-on time, and servo voltage on response variables, namely kerf width (KW), cutting speed (CS), material removal rate (MRR), and surface roughness (Ra) for WEDM of DC53 steel. Taguchi L18 orthogonal array was used for experimental design. Analysis of variance showed that sparks on duration is the most significant factor affecting KW, CS, and MRR with percentage contribution of 48.25 %, 80.21 %, and 45.21 %, respectively. Optimal set of machining parameters resulted in 14.02 % improvement in MRR and 19.24 % reduction in workpiece surface roughness. Moreover, gamma phase coated wire was found to have 30–35 % faster cutting rate as compared to uncoated brass wire.

KW - Analysis of variance

KW - Cutting speed

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KW - Gamma phase wire electrode

KW - Signal to noise ratio

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Parametric optimization in wire electric discharge machining of DC53 steel using gamma phase coated wire

Abstract

Bibliographical note

UN SDGs

Keywords

ASJC Scopus subject areas

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