Chapter 14 Recycled Ti-17 Based Composite Design; Optimization Process Parameters in Wire Cut Electrical Discharge Machining (WEDM) Sonia Ezeddini, Mohamed Boujelbene, Emin Bayraktar, and Sahbi Ben Salem Abstract This work present a comprehensive study on the effect and optimization of machining parameters on the kerf (cutting width) and material removal rate (MRR) in wire electrical discharge machining (WEDM) process by using the response surface methodology (RSM) and Taguchi method. The experimental studies were conducted under varying parameters. The main input parameters on this model are the cutting parameters such us pulse on time (Ton), servo voltage (U), Speed of advance or feed rate (S) and injection pressure or flushing pressure (P). Recycled Titanium based composite (an alloy Ti17) was used for machining operations and the combined effects of cutting parameters on the material removal MRR rate and kerf were investigated while using the analysis of variance ANOVA. Mathematical models were used for the objective of minimum kerf and maximum MRR, Cut edge surface analysis was carried out using an optic microscope and Scanning Electron Microscope (SEM) to evaluate the kerf. Keywords WEDM· ANOVA · Taguchi method · MRR · Kerf (cutting width) · Recycled composites · Ti17 14.1 Introduction Electrical discharge machining (EDM) an important non-conventional manufacturing method used for hard to cut conductive material and has been accepted worldwide as a standard process in the manufacture of forming tools to produce plastics mouldings, forming dies, die casting, since it does not require cutting tools and allows machining involving hard, brittle, thin and complex geometry. Wire electrical discharge machining (WEDM) is now used in automobile, aérospace and medical industries, as good as in practically all areas of conductive material machining. WEDM is based on electric discharge machining process and it is an unconventional method of machining that includes electrically conductive materials, and involves the removal of material by the action of energy dissipated between an electrode and a workpiece. This process has kneed important progress that made it a lead of machining processes of precision and many several researchers are studied these process and their different aspects. It is the machining process during which material is eroded by series of controlled sparks between electrode and the workpiece. Workpiece and the electrode are immersed in the dielectric fluid. The area around the spark is heated to 10,000–20,000 ◦C and the dielectric fluid around this area is vaporized, leading to increase in the pressure. Also small amount of workpiece and electrode material melts and vaporizes, which creates small craters on the surface. A layer of melted and resolidified material called recast can be found on the surface after EDM [1–7]. I was observed from the intensive literature review that most of the studies have target the optimization of multiple quality characteristics in WEDM process such as cutting rate, wire wear rate and wire failure frequency, kerf size, Material removal rate MRR and most important quality of machined surface the surface roughness SR. Those characteristics are influenced by machining parameters. Optimization of these parameters for each material or groupe of materials is necessary [1, 9]. S. Ezeddini · M. Boujelbene · S. Ben Salem University of Tunis El Manar, ENIT, École Nationale d’Ingénieurs de Tunis, Tunis, Tunisia E. Bayraktar ( ) Supmeca-Paris, School of Mechanical and Manufacturing Engineering, Saint-Ouen, Paris, France e-mail: bayraktar@supmeca.fr © The Society for Experimental Mechanics, Inc. 2019 P. R. Thakre et al. (eds.), Mechanics of Composite, Hybrid and Multifunctional Materials, Volume 5, Conference Proceedings of the Society for Experimental Mechanics Series, https://doi.org/10.1007/978-3-319-95510-0_14 109
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