Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM
AZ91 magnesium alloys have poor machinability when conventional chip removal processes are used due to their low thermal stability and high susceptibility to softening and oxidation at elevated temperatures, which lead to excessive tool wear, poor surface quality, and deformation-induced machining...
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| Format: | Article |
| Language: | English |
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CTU Central Library
2025-07-01
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| Series: | Acta Polytechnica |
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| Online Access: | https://ojs.cvut.cz/ojs/index.php/ap/article/view/10074 |
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| author | Levent Urtekin Faik Yılan İbrahim Baki Şahin Kadir Gök |
| author_facet | Levent Urtekin Faik Yılan İbrahim Baki Şahin Kadir Gök |
| author_sort | Levent Urtekin |
| collection | DOAJ |
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AZ91 magnesium alloys have poor machinability when conventional chip removal processes are used due to their low thermal stability and high susceptibility to softening and oxidation at elevated temperatures, which lead to excessive tool wear, poor surface quality, and deformation-induced machining challenges. This study investigated the impact of wire electrical discharge machining (WEDM) parameters on material removal rate (MRR) and surface roughness (SR) using magnesium. For this purpose, an analysis of variance (ANOVA) and Grey Relational Analysis (GRA) were performed to find the optimal settings. Findings indicate that pulse-on time (Ton) significantly affects both MRR and SR: higher Ton increases MRR but worsens SR, while shorter Ton improves SR but reduces MRR. Pulse-off time (Toff) and wire feed rate (WF) have secondary effects. Longer Toff improves surface quality but slightly reduces MRR, and lower WF improves cutting efficiency and MRR. The optimal settings identified by the Taguchi method were observed to be 123 μs Ton, 55 μs Toff, and 6 mmin−1 WF for high MRR; and 123 μs Ton, 58 μs Toff, and 4 mmin−1 WF for reduced SR. In summary, understanding how WEDM parameters affect MRR and SR allows manufacturers to achieve efficient material removal and desired surface quality.
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| format | Article |
| id | doaj-art-d30890f7d0b6415e9109000c6ceed8ba |
| institution | DOAJ |
| issn | 1805-2363 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | CTU Central Library |
| record_format | Article |
| series | Acta Polytechnica |
| spelling | doaj-art-d30890f7d0b6415e9109000c6ceed8ba2025-08-20T03:16:46ZengCTU Central LibraryActa Polytechnica1805-23632025-07-0165310.14311/AP.2025.65.0361Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDMLevent Urtekin0https://orcid.org/0000-0003-4348-4749Faik Yılan1https://orcid.org/0000-0001-7166-8604İbrahim Baki Şahin2https://orcid.org/0000-0001-8090-9748Kadir Gök3https://orcid.org/0000-0001-5736-1884Kırşehir Ahi Evran University, Faculty of Engineering and Architecture, Department of Mechanical Engineering, 40100 Kırşehir, TurkeyKırşehir Ahi Evran University, Faculty of Engineering and Architecture, Department of Mechanical Engineering, 40100 Kırşehir, TurkeyKırşehir Ahi Evran University, Faculty of Engineering and Architecture, Department of Mechanical Engineering, 40100 Kırşehir, Turkeyİzmir Bakırçay University, Engineering and Architecture Faculty, Department of Biomedical Engineering, 35660 İzmir, Turkey AZ91 magnesium alloys have poor machinability when conventional chip removal processes are used due to their low thermal stability and high susceptibility to softening and oxidation at elevated temperatures, which lead to excessive tool wear, poor surface quality, and deformation-induced machining challenges. This study investigated the impact of wire electrical discharge machining (WEDM) parameters on material removal rate (MRR) and surface roughness (SR) using magnesium. For this purpose, an analysis of variance (ANOVA) and Grey Relational Analysis (GRA) were performed to find the optimal settings. Findings indicate that pulse-on time (Ton) significantly affects both MRR and SR: higher Ton increases MRR but worsens SR, while shorter Ton improves SR but reduces MRR. Pulse-off time (Toff) and wire feed rate (WF) have secondary effects. Longer Toff improves surface quality but slightly reduces MRR, and lower WF improves cutting efficiency and MRR. The optimal settings identified by the Taguchi method were observed to be 123 μs Ton, 55 μs Toff, and 6 mmin−1 WF for high MRR; and 123 μs Ton, 58 μs Toff, and 4 mmin−1 WF for reduced SR. In summary, understanding how WEDM parameters affect MRR and SR allows manufacturers to achieve efficient material removal and desired surface quality. https://ojs.cvut.cz/ojs/index.php/ap/article/view/10074AZ91WEDMmaterial removal rate (MRR)surface roughness (SR)optimisation |
| spellingShingle | Levent Urtekin Faik Yılan İbrahim Baki Şahin Kadir Gök Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM Acta Polytechnica AZ91 WEDM material removal rate (MRR) surface roughness (SR) optimisation |
| title | Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM |
| title_full | Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM |
| title_fullStr | Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM |
| title_full_unstemmed | Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM |
| title_short | Analysis of surface roughness and machining performance of AZ91 magnesium alloy cut by WEDM |
| title_sort | analysis of surface roughness and machining performance of az91 magnesium alloy cut by wedm |
| topic | AZ91 WEDM material removal rate (MRR) surface roughness (SR) optimisation |
| url | https://ojs.cvut.cz/ojs/index.php/ap/article/view/10074 |
| work_keys_str_mv | AT leventurtekin analysisofsurfaceroughnessandmachiningperformanceofaz91magnesiumalloycutbywedm AT faikyılan analysisofsurfaceroughnessandmachiningperformanceofaz91magnesiumalloycutbywedm AT ibrahimbakisahin analysisofsurfaceroughnessandmachiningperformanceofaz91magnesiumalloycutbywedm AT kadirgok analysisofsurfaceroughnessandmachiningperformanceofaz91magnesiumalloycutbywedm |