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A Novel Flushing Mechanism to Minimize Roughness and Dimensional Errors during Wire Electric Discharge Machining of
Muhammad Umar Farooq1, Saqib Anwar2, M Saravana Kumar3
1School of Mechanical Engineering, University of Leeds, Leeds LS2 9JT, UK.
Materials (Basel, Switzerland)
|October 27, 2022
Summary
This study investigates wire electric discharge machining for aeronautical components, optimizing flushing parameters to enhance precision and surface quality in Inconel 718. Results show significant reductions in geometric errors and improved spark gap formation.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Aerospace Engineering
Background:
- Aeronautical industry demands cost-effective, high-performance engine components with complex geometries, precise dimensions, and superior surface quality.
- Wire Electric Discharge Machining (WEDM) is a key technology for manufacturing such components.
- The influence of flushing parameters in WEDM, crucial for process efficiency and quality, remains underexplored.
Purpose of the Study:
- To investigate the impact of WEDM flushing attributes on Inconel 718.
- To analyze the effects of servo voltage, flushing pressure, nozzle diameter, and nozzle-workpiece distance on geometrical errors, spark gap, and surface roughness.
- To optimize WEDM process parameters for improved component quality and manufacturing efficiency.
Main Methods:
- Analysis of four process variables: servo voltage, flushing pressure, nozzle diameter, and nozzle-workpiece distance.
- Evaluation of geometrical errors (angular and radial deviations), spark gap formation, and arithmetic roughness.
- Application of statistical analysis, microscopical analysis, and grey relational analysis for mono- and multi-objective optimization.
Main Results:
- Grey relational analysis identified optimal parameters leading to a 0.109 mm spark gap, 0.956% angular deviation, 3.49% radial deviation, and 2.2 µm surface roughness.
- A novel flushing mechanism demonstrated a 1.92% improvement in spark gap.
- The new flushing approach reduced angular and radial deviations by 8.24% and 29.11%, respectively.
Conclusions:
- Flushing attributes significantly influence WEDM performance and the quality of Inconel 718 components.
- Process optimization using grey relational analysis effectively minimizes geometrical errors and enhances surface finish.
- The developed novel flushing mechanism offers a viable method for improving precision and efficiency in WEDM for aerospace applications.
