Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material

Recently, the machining of precise cylindrical forms on hard and difficult-to-cut materials by spark erosion has gained popularity. However, the performance of this process always reflects the drawbacks in terms of distortion in gap equilibrium due to sensitivity of rotating workpieces in which the...

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Main Author:	Mohd Zakaria, Muhammad Akmal
Format:	Thesis
Language:	English English
Published:	2023
Subjects:	T Technology (General) TJ Mechanical engineering and machinery
Online Access:	http://eprints.utem.edu.my/id/eprint/28299/1/Performance%20evaluation%20of%20ultrasonic%20assisted%20wire%20electrical%20discharge%20turning%20for%20TI-6AL-4V%20material.pdf http://eprints.utem.edu.my/id/eprint/28299/2/Performance%20evaluation%20of%20ultrasonic%20assisted%20wire%20electrical%20discharge%20turning%20for%20TI-6AL-4V%20material.pdf
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spelling	my-utem-ep.282992024-12-16T08:26:12Z Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material 2023 Mohd Zakaria, Muhammad Akmal T Technology (General) TJ Mechanical engineering and machinery Recently, the machining of precise cylindrical forms on hard and difficult-to-cut materials by spark erosion has gained popularity. However, the performance of this process always reflects the drawbacks in terms of distortion in gap equilibrium due to sensitivity of rotating workpieces in which the surface finish of the machined parts and the material removal rate (MRR) are not satisfying even when advanced computing and statistical optimisation methods have been used to obtain the best machining conditions. Solving the conflict of MRR and surface roughness is challenging because no single combination of parameters can provide the best machining performance. Therefore, the main objective of this research is to evaluate the performance of ultrasonic assisted in wire electrical discharge turning (WEDT) for Ti-6Al-4V on MRR and surface roughness. The ultrasonic attachment accessories are fabricated and retrofitted into the existing WEDT. The collected data for parametric study is analysed by analysis of variance (ANOVA). For the evaluation of surface roughness, five machining paths are evaluated on the basis of conventional turning operations, such as straight-turning and cone angle. The machined surface conditions are characterised by elemental analysis and surface morphology in post-evaluation measurement. Results showed that, the integration of ultrasonic vibration to WEDT revealed positive effects, where the average of MRR and surface roughness are improved by 2.9% and 13.4%, respectively, even though the proposed ultrasonic parameters have not been optimised yet. The electrode wire debris generated during machining, which can resolidify to the machined surface, is able to be reduced with the integration of ultrasonic vibration to WEDT machining when using low ultrasonic amplitude (10 μm). After performing with multi-objective parameter optimization with the goal of maximising the MRR and minimising the surface roughness using genetic algorithm method, there is a 5.2% improvement for the MRR and 11.6%–27.9% improvement for surface roughness compared to conventional WEDT. In conclusion, this study successfully applied the ultrasonic vibration to rotating workpieces, proved the capability in machining and enhanced both MRR and surface roughness. 2023 Thesis http://eprints.utem.edu.my/id/eprint/28299/ http://eprints.utem.edu.my/id/eprint/28299/1/Performance%20evaluation%20of%20ultrasonic%20assisted%20wire%20electrical%20discharge%20turning%20for%20TI-6AL-4V%20material.pdf text en public http://eprints.utem.edu.my/id/eprint/28299/2/Performance%20evaluation%20of%20ultrasonic%20assisted%20wire%20electrical%20discharge%20turning%20for%20TI-6AL-4V%20material.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=123808 phd doctoral Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Raja Abdullah, Raja Izamshah
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Raja Abdullah, Raja Izamshah
topic	T Technology (General) TJ Mechanical engineering and machinery
spellingShingle	T Technology (General) TJ Mechanical engineering and machinery Mohd Zakaria, Muhammad Akmal Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material
description	Recently, the machining of precise cylindrical forms on hard and difficult-to-cut materials by spark erosion has gained popularity. However, the performance of this process always reflects the drawbacks in terms of distortion in gap equilibrium due to sensitivity of rotating workpieces in which the surface finish of the machined parts and the material removal rate (MRR) are not satisfying even when advanced computing and statistical optimisation methods have been used to obtain the best machining conditions. Solving the conflict of MRR and surface roughness is challenging because no single combination of parameters can provide the best machining performance. Therefore, the main objective of this research is to evaluate the performance of ultrasonic assisted in wire electrical discharge turning (WEDT) for Ti-6Al-4V on MRR and surface roughness. The ultrasonic attachment accessories are fabricated and retrofitted into the existing WEDT. The collected data for parametric study is analysed by analysis of variance (ANOVA). For the evaluation of surface roughness, five machining paths are evaluated on the basis of conventional turning operations, such as straight-turning and cone angle. The machined surface conditions are characterised by elemental analysis and surface morphology in post-evaluation measurement. Results showed that, the integration of ultrasonic vibration to WEDT revealed positive effects, where the average of MRR and surface roughness are improved by 2.9% and 13.4%, respectively, even though the proposed ultrasonic parameters have not been optimised yet. The electrode wire debris generated during machining, which can resolidify to the machined surface, is able to be reduced with the integration of ultrasonic vibration to WEDT machining when using low ultrasonic amplitude (10 μm). After performing with multi-objective parameter optimization with the goal of maximising the MRR and minimising the surface roughness using genetic algorithm method, there is a 5.2% improvement for the MRR and 11.6%–27.9% improvement for surface roughness compared to conventional WEDT. In conclusion, this study successfully applied the ultrasonic vibration to rotating workpieces, proved the capability in machining and enhanced both MRR and surface roughness.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Mohd Zakaria, Muhammad Akmal
author_facet	Mohd Zakaria, Muhammad Akmal
author_sort	Mohd Zakaria, Muhammad Akmal
title	Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material
title_short	Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material
title_full	Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material
title_fullStr	Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material
title_full_unstemmed	Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material
title_sort	performance evaluation of ultrasonic assisted wire electrical discharge turning for ti-6al-4v material
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2023
url	http://eprints.utem.edu.my/id/eprint/28299/1/Performance%20evaluation%20of%20ultrasonic%20assisted%20wire%20electrical%20discharge%20turning%20for%20TI-6AL-4V%20material.pdf http://eprints.utem.edu.my/id/eprint/28299/2/Performance%20evaluation%20of%20ultrasonic%20assisted%20wire%20electrical%20discharge%20turning%20for%20TI-6AL-4V%20material.pdf
_version_	1818612068376379392

Performance evaluation of ultrasonic assisted wire electrical discharge turning for TI-6AL-4V material

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