Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes
Machining thicker workpieces in the process of Wire Electrical Discharge Machining (WEDM) can result in a concave phenomenon known as a “drum shape error” due to the vibration of wires and accumulation of debris, which leads to secondary discharge in the middle of the workpiece. Reducing the drum sh...
Saved in:
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2024-12-01
|
| Series: | Machines |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-1702/12/12/908 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850242038277079040 |
|---|---|
| author | Shih-Ming Wang Li-Jen Hsu Hariyanto Gunawan Ren-Qi Tu |
| author_facet | Shih-Ming Wang Li-Jen Hsu Hariyanto Gunawan Ren-Qi Tu |
| author_sort | Shih-Ming Wang |
| collection | DOAJ |
| description | Machining thicker workpieces in the process of Wire Electrical Discharge Machining (WEDM) can result in a concave phenomenon known as a “drum shape error” due to the vibration of wires and accumulation of debris, which leads to secondary discharge in the middle of the workpiece. Reducing the drum shape error typically requires a longer finishing process. Finding a balance between precision and machining time efficiency has become a challenge for modern machining shops. This study employed experimental analysis to investigate the effect of individual parameters on the shape error and machining removal rate (MRR). Key influential parameters, including open voltage (OV), pulse ON time (ON), pulse OFF time (OFF), and servo voltage (SV), were chosen for data collection using full factorial and Taguchi orthogonal arrays. Regression analysis was conducted to establish multiple regression equations. These equations were used to develop optimization rules, and subsequently, a user-friendly human–machine interface was developed using C# based on these optimization rules to create a shape error and MRR optimization system. The system can predict the optimal parameter combinations to minimize the shape error and increase the MRR. The results of the verification experiments showed that the prediction accuracy can reach 94.7% for shape error and 99.2% for MRR. Additionally, the shape error can be minimized by up to 40%. |
| format | Article |
| id | doaj-art-9c4110995dba40e9831de4ba5db6e2ac |
| institution | OA Journals |
| issn | 2075-1702 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj-art-9c4110995dba40e9831de4ba5db6e2ac2025-08-20T02:00:24ZengMDPI AGMachines2075-17022024-12-01121290810.3390/machines12120908Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining ProcessesShih-Ming Wang0Li-Jen Hsu1Hariyanto Gunawan2Ren-Qi Tu3Department of Mechanical Engineering, National Chung Hsing University, Taichung 40227, TaiwanDepartment of Mechanical Engineering, Chung Yuan Christian University, Taoyuan 320314, TaiwanDepartment of Mechanical Engineering, Chung Yuan Christian University, Taoyuan 320314, TaiwanDepartment of Mechanical Engineering, Chung Yuan Christian University, Taoyuan 320314, TaiwanMachining thicker workpieces in the process of Wire Electrical Discharge Machining (WEDM) can result in a concave phenomenon known as a “drum shape error” due to the vibration of wires and accumulation of debris, which leads to secondary discharge in the middle of the workpiece. Reducing the drum shape error typically requires a longer finishing process. Finding a balance between precision and machining time efficiency has become a challenge for modern machining shops. This study employed experimental analysis to investigate the effect of individual parameters on the shape error and machining removal rate (MRR). Key influential parameters, including open voltage (OV), pulse ON time (ON), pulse OFF time (OFF), and servo voltage (SV), were chosen for data collection using full factorial and Taguchi orthogonal arrays. Regression analysis was conducted to establish multiple regression equations. These equations were used to develop optimization rules, and subsequently, a user-friendly human–machine interface was developed using C# based on these optimization rules to create a shape error and MRR optimization system. The system can predict the optimal parameter combinations to minimize the shape error and increase the MRR. The results of the verification experiments showed that the prediction accuracy can reach 94.7% for shape error and 99.2% for MRR. Additionally, the shape error can be minimized by up to 40%.https://www.mdpi.com/2075-1702/12/12/908WEDMdrum errorregressionsurface processing speed |
| spellingShingle | Shih-Ming Wang Li-Jen Hsu Hariyanto Gunawan Ren-Qi Tu Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes Machines WEDM drum error regression surface processing speed |
| title | Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes |
| title_full | Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes |
| title_fullStr | Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes |
| title_full_unstemmed | Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes |
| title_short | Optimization of Machining Parameters for Reducing Drum Shape Error Phenomenon in Wire Electrical Discharge Machining Processes |
| title_sort | optimization of machining parameters for reducing drum shape error phenomenon in wire electrical discharge machining processes |
| topic | WEDM drum error regression surface processing speed |
| url | https://www.mdpi.com/2075-1702/12/12/908 |
| work_keys_str_mv | AT shihmingwang optimizationofmachiningparametersforreducingdrumshapeerrorphenomenoninwireelectricaldischargemachiningprocesses AT lijenhsu optimizationofmachiningparametersforreducingdrumshapeerrorphenomenoninwireelectricaldischargemachiningprocesses AT hariyantogunawan optimizationofmachiningparametersforreducingdrumshapeerrorphenomenoninwireelectricaldischargemachiningprocesses AT renqitu optimizationofmachiningparametersforreducingdrumshapeerrorphenomenoninwireelectricaldischargemachiningprocesses |