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Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses

Stainless steel (SS 304) is commonly employed in industrial applications due to its considerable corrosion resistance, thermal resistance, and ductility. Most of its intended applications require the formation of complex profiles, which justify the use of wire electrical discharge machining (WEDM)....

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Autores principales: Ishfaq, Kashif, Ahmad, Naveed, Jawad, Muhammad, Ali, Muhammad Asad, M. Al-Ahmari, Abdulrahman
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2019
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6631865/
https://www.ncbi.nlm.nih.gov/pubmed/31212883
http://dx.doi.org/10.3390/ma12121940
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author Ishfaq, Kashif
Ahmad, Naveed
Jawad, Muhammad
Ali, Muhammad Asad
M. Al-Ahmari, Abdulrahman
author_facet Ishfaq, Kashif
Ahmad, Naveed
Jawad, Muhammad
Ali, Muhammad Asad
M. Al-Ahmari, Abdulrahman
author_sort Ishfaq, Kashif
collection PubMed
description Stainless steel (SS 304) is commonly employed in industrial applications due to its considerable corrosion resistance, thermal resistance, and ductility. Most of its intended applications require the formation of complex profiles, which justify the use of wire electrical discharge machining (WEDM). However, its high thermal resistance imposes a limitation on acquiring adequate surface topography because of the high surface tension of the melt pool, which leads to the formation of spherical modules; ultimately, this compromises the surface quality. Furthermore, the stochastic nature of the process makes it difficult to optimize its performance, especially if more than one conflicting response is involved, such as high cutting speed with low surface roughness and kerf width. Therefore, this study aimed to comprehensively investigate the interaction of SS 304 and WEDM, with a prior focus on simultaneously optimizing all the conflicting responses using the Taguchi-based grey relational approach. Analysis of variance (ANOVA) revealed that the current was the most significant parameter for cutting speed and kerf, whereas roughness, voltage (45%), drum speed (25.8%), and nozzle offset distance (~21%) were major contributing factors. SEM micrographs showed that optimal settings not only ensured simultaneous optimization of the conflicting responses but also reduced the number and size of spherical modules.
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spelling pubmed-66318652019-08-19 Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses Ishfaq, Kashif Ahmad, Naveed Jawad, Muhammad Ali, Muhammad Asad M. Al-Ahmari, Abdulrahman Materials (Basel) Article Stainless steel (SS 304) is commonly employed in industrial applications due to its considerable corrosion resistance, thermal resistance, and ductility. Most of its intended applications require the formation of complex profiles, which justify the use of wire electrical discharge machining (WEDM). However, its high thermal resistance imposes a limitation on acquiring adequate surface topography because of the high surface tension of the melt pool, which leads to the formation of spherical modules; ultimately, this compromises the surface quality. Furthermore, the stochastic nature of the process makes it difficult to optimize its performance, especially if more than one conflicting response is involved, such as high cutting speed with low surface roughness and kerf width. Therefore, this study aimed to comprehensively investigate the interaction of SS 304 and WEDM, with a prior focus on simultaneously optimizing all the conflicting responses using the Taguchi-based grey relational approach. Analysis of variance (ANOVA) revealed that the current was the most significant parameter for cutting speed and kerf, whereas roughness, voltage (45%), drum speed (25.8%), and nozzle offset distance (~21%) were major contributing factors. SEM micrographs showed that optimal settings not only ensured simultaneous optimization of the conflicting responses but also reduced the number and size of spherical modules. MDPI 2019-06-17 /pmc/articles/PMC6631865/ /pubmed/31212883 http://dx.doi.org/10.3390/ma12121940 Text en © 2019 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Ishfaq, Kashif
Ahmad, Naveed
Jawad, Muhammad
Ali, Muhammad Asad
M. Al-Ahmari, Abdulrahman
Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
title Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
title_full Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
title_fullStr Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
title_full_unstemmed Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
title_short Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
title_sort evaluating material’s interaction in wire electrical discharge machining of stainless steel (304) for simultaneous optimization of conflicting responses
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6631865/
https://www.ncbi.nlm.nih.gov/pubmed/31212883
http://dx.doi.org/10.3390/ma12121940
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