NIT Rourkela

Seminar Title

Experimental and Numerical Investigations of Machining Ti-6Al-4V Spur Gears Using WEDM Process

Seminar Type

Defence Seminar

Department

Mechanical Engineering

Speaker Type

Student

Speaker Name

Kasinath Das Mohapatra

Date & Time

26 Oct 2018 11:00 AM

Venu

Seminar Room (Department of Mechanical Engineering)

Contact

Prof. Alok Satapathy, Department of Mechanical Engineering

Abstract

Wire Electric Discharge Machining (WEDM) is one of the novel machining methods that involves machining of complex shapes and geometries of metals with better surface finish and accuracy by the help of electrical sparks. It has wide range of importance and applications in producing parts used in electrical, automobile, biomedical, aerospace, etc. industries. The present research deals with the manufacturing of spur gear made of Titanium alloy, Ti-6Al-4V machined with wire EDM to obtain optimized settings at different working conditions. Experimental investigations are carried out by varying four input factors i.e. pulse on time, pulse off time, wire feed rate and servo voltage at three different levels each. The experimental results confirmed that with the increase in the pulse on time, the response parameters i.e. MRR, kerf width, surface roughness and wire wear rate also increases machined by all the three wire electrodes (Uncoated brass, Brass wire with diffused coated zinc, Brass wire with rich coated zinc). The output responses for WEDM and the gears have been optimized and predicted using TOPSIS based GA and ANFIS technique respectively in order to get an optimized setting. The microstructural analysis and measurements have been carried out for both the machined workpiece and the wire surface at obtained optimized settings. The numerical modeling is accomplished using ANSYS® for both the workpiece and the wire. The experimental results of the conventional WEDM are also compared with that obtained from ultrasonic vibration assisted (UVA) wire EDM giving vibration to the workpiece in order to study the effects of process parameters on different responses. The results confirmed that UVA-WEDM can be successfully employed to machine gears due to its higher machining rate neglecting the surface roughness of the gear. From all the above investigations it is observed that uncoated brass wire is more suitable and convenient in machining gears followed by brass wire with diffused coated zinc and brass wire with rich coated zinc electrode subsequently.

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