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Effect of hybrid wire EDM conditions on generation of residual stresses in machining of HCHCr D2 tool steel under ultrasonic vibration

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Abstract

This experimental examination exhibit a novel Hybrid Wire electrical discharge machining (H-WEDM) process of ultrasonic vibration combined with traditional Wire-EDM. The metal cutting for form tool and extrusion die with WEDM is liked to give better surface morphology. The effect of residual stresses has been dissected for H-WEDMed machined surface alongside the surface roughness and erosion rate to enhance surface integrity and longer service life of High Carbon High Chromium D2 tool steel. The process parameters chose for this investigation are type of vibration continuous/discontinues, amplitude of vibration, workpiece dimension, duty cycle, peek current and wire feed rate with objective to optimize the residual stresses and erosion rate. Portable X-ray Residual Stress Analyzer, a non-destructive X-ray analyzer is used to measure the residual stress efficiently by detecting the full Debye ring data from a single incident X-ray angle and Non goniometer stage influence on the measurements. An endeavor was made to compare the residual stresses for continuous/discontinues vibration and without vibration. The impacts of amplitude of vibration, peak current, duty cycle and wire feed rate variations on erosion rate was study using Taguchi method. From experimental study, it was observed that discontinuous vibration enhances the erosion rate and diminishes the resultant stresses. High Peak current and duty cycle altogether deteriorate the surface texture, which creates high tensile residual stresses because of debris and micro cracks. The optimum value of residual stresses 86.53 MPa and material erosion rate 6.45 mm/min was achieved using H-WEDM.

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Acknowledgements

The authors acknowledge Department Mechanical Engineering, YMCA UST Faridabad, India, for providing the necessary wire electric discharge machine tool with additional set-up for experimentation. The authors are also thankful to Department of Mechanical and Production, DTU Delhi, India, for providing stress analyzer facility.

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Authors and Affiliations

  1. Department of Mechanical Engineering, YMCA University of Science and Technology, Faridabad, Haryana, 121006, India

    Sanjay Kumar & Sandeep Grover

  2. Department of Mechanical, Production and Industrial and Automation, Delhi Technological University, Delhi, 110042, India

    R. S. Walia

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  1. Sanjay Kumar
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  2. Sandeep Grover
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  3. R. S. Walia
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Correspondence to Sanjay Kumar.

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Kumar, S., Grover, S. & Walia, R.S. Effect of hybrid wire EDM conditions on generation of residual stresses in machining of HCHCr D2 tool steel under ultrasonic vibration. Int J Interact Des Manuf 12, 1119–1137 (2018). https://doi.org/10.1007/s12008-018-0474-8

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  • DOI: https://doi.org/10.1007/s12008-018-0474-8

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