ANALYSIS AND OPTIMIZATION OF SURFACE INTEGRITY IN WIRE ELECTRICAL DISCHARGE MACHINING PROCES

malak hussein jabar; Ali  Abbar Khleif; Qussay  Salah Mahdi

doi:10.30572/2018/KJE/170301

Authors

malak hussein jabar Department of Production Engineering and Metallurgy University of Technology-Iraq, Baghdad, Iraq
Ali Abbar Khleif Department of Production Engineering and Metallurgy University of Technology-Iraq, Baghdad, Iraq
Qussay Salah Mahdi Department of Production Engineering and Metallurgy University of Technology-Iraq, Baghdad, Iraq

DOI:

https://doi.org/10.30572/2018/KJE/170301

Keywords:

Wire electrical discharge machining, Surface integrity, Surface roughness, Recast layer, Stainless steel 1610

Abstract

Wire Electrical Discharge Machining (WEDM) process is one of the most important and effective technologies in modern manufacturing due to its versatility in producing complex-shaped components with high precision. It can be used to machine various hard materials and non-ferrous metals regardless of their hardness. In general, surface integrity includes several tests such as surface roughness tests, recast layer measurement, microhardness testing, residual stress measurement, microstructural analysis, chemical and metallurgical tests and fatigue and wear testing. The present study focused on evaluating surface roughness and recast layer of stainless steel 1610 which has many applications like tubes industry and tools, also it has been noticed that a little studies focused on it in the survey. The study was conducted by selecting three variable parameters: servo feed (400, 500,600 m/min), pulse-on time (24,28,32 µs) and pulse-off time (36,40,44 µs) which have the greatest role on the process, while keeping the other machine parameters constant. The obtained data were analyzed using (ANOVA) which was satisfied for predicting and explain the relation between the input parameters and the process characteristics, and it was found that a smoother product surface can be achieved by reducing the values of servo feed (SF) and pulse on time (T_ON) while increasing the pulse off time (T_OFF). As for the recast layer, it increased proportionally with SF and T_ONand began to stabilize at higher levels of T_OFF

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