International Journal of Modern Manufacturing Technologies

ISSN 2067–3604, Vol. IX, No. 2/2017 1

INFLUENCE OF SELECTED HYDROMECHANICAL PARAMETERS OF

WEDM MACHINE OPERATION ON QUALITY AND CUTTING
PERFORMANCE
Łukasz Łomozik1, Henryk Bąkowski 2 , Andrzej Sokołowski3
1
Sm Hydro, 10B Karolinki Street, 40-467 Katowice, Poland
2
Silesian University of Technology, Faculty of Transport, 8 Krasinskiego Street, 40-019 Katowice, Poland
3
Silesian University of Technology, Faculty of Mechanical Engineering, 18A Konarskiego Street, 44-100 Gliwice, Poland

Corresponding author : Andrzej Sokołowski, [email protected]

Abstract: The article presents the impact of selected that the increase in current and pulse time corresponds
hydromechanical parameters of Wire Electrical Discharge to an increase in the amount of material removed in a
Machining (WEDM) on the quality and efficiency of single pulse, generating craters that create surface
cutting, i.e. the surface roughness and the material removal roughness. However, this relationship is not directly
rate. Based on the literature analysis and own experience,
proportional. Similar results were obtained by the
the following parameters of the WEDM operation were
considered: the wire feeding speed, the pressure of the authors of the paper [2].
dielectric fluid and the speed of the working head. Using the Paper [3] describes the influence of wire tension
parameter values recommended by the machine and wire rewinding speed (wire feeding speed) on
manufacturer, preliminary tests were carried out. The cut machining rate. It has been shown that stable
out element was the satellite of the satellite mechanism machining (cutting) can be achieved with a minimum
being part of a low-power hydraulic motor. Observations of wire rewinding speed of 4 m/min. [4]. The quoted
the surface determined the presence of numerous erosive papers also present some evidence that as the wire
craters on the tested surface. Based on the results obtained, speed increases, the surface roughness first increases
three-dimensional charts were developed showing the and afterward decreases. An increase in wire tension,
impact of selected input parameters on the considered
on the other hand, reduces roughness.
output factor. The conducted research may constitute the
basis for optimization of the electro-erosion cutting process. This paper aimed at analyzing the influence of
Keywords: WEDM, hydromechanical parameters, surface hydromechanical parameters, i.e. feed rate of the
roughness, optimization. working head, wire rewinding speed and dielectric
fluid flow speed on the surface roughness of cut parts.
1. INTRODUCTION Based on the results obtained, three-dimensional
charts were developed, determined from the second-
The electro-discharge cutting process is well degree polynomial function, showing the impact of
known for its high economic benefits and degree of selected input parameters on the considered output
machining accuracy. Since its introduction in 1969, factor.
enormous progress has been made in terms of cutting
speed, which is now 4-6 higher and 3-4 times more 2. TEST PROCEDURE
accurate. Due to the increasing importance of electro-
discharge cutting in the industry along with the To shorten the test time, an experimental plan based
increasing demands on accuracy and economy of on Hartley's special polyselective test plan on a
technological processes, there is a need for careful hypercube with three repetitions was used (Fig. 1). The
research over the impact exerted by the electro- use of the three-level plan allowed to obtain
discharge machining on the quality and effectiveness mathematical models of the studied process in the
of the cutting. Unfortunately, due to the complexity of form of the second-degree polynomial [5]:
physical phenomena occurring during machining,
despite numerous years of research in this field, no = +∑ + ∑ + ∑
fully accurate picture of phenomena occurring during
the shaping of workpieces has been obtained so far. In the planned experiment, the input factors (assumed
The paper [1] presents the effect of discharge pulse independent variables) were coded on three levels
time and current intensity in the pulse on the efficiency (Tab. 1). Input factor levels in the relevant cutting
of the material removal process and selected trials were set according to the matrix of the selected
parameters of the roughness profile. It has been proven experiment plan (Tab. 2).
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selected mechanical properties are listed in Table 4.
The material was delivered as 280x150x10 plates.
The material was used to cut out the satellites (Fig.
2) of the satellite mechanism, which is a part of the
hydraulic engine (Fig. 3) of SM Hydro.

Table 4. Selected mechanical properties of alloy

steel [6]
Trade Tensile
Density Hardness Yield point;
name of strength;
[g/cm3] HB Re, MPa
steel Rm, MPa
IMPAX 7.8 330 1020 900

Stator

Rotor

Fig. 1. Graphic interpretation of the three-level Pressure chamber

experimental plan [5]

Table 1. Levels of factors on a standardized scale

Standardized scale factor level, Satellite
-1 corresponding to the minimum value of the
parameter concerned
Standardized scale factor level, Fig. 2. Satellite mechanism
0 corresponding to the average value of the
parameter concerned
Standardized scale factor level,
1 corresponding to the maximum value of the
parameter concerned
Satellite
Table 2. Hartley's plan matrix mechanism
Test Controlled factors on a standardized scale
Fig. 3. View of the disassembled hydraulic motor [7]
No
X1 X2 X3
Experimental tests were carried out on a Sodic AG
1 -1 -1 1 600L EDM electrical discharge machine. The working
2 1 -1 -1 electrode was CuZn37 brass wire of 0.2 mm diameter
3 -1 1 -1 and 900 N/mm2 strength. The electric medium was
4 1 1 1 distilled and deionized water with a resistance of R =
5 -1 0 0 5·104 Ωcm.
6 1 0 0 The surface roughness of cut parts was measured
on the SRT-6210 needle profile meter (Fig. 4).
7 0 -1 0
8 0 1 0
9 0 0 -1
10 0 0 1
11 0 0 0

Table 3. Chemical composition of the alloy steel used

in the tests

2.1 Materials and equipment used in the tests

Fig. 4. Needle profile meter SRT-6200
The tests were carried out on chromium-nickel-
molybdenum alloy steel 40CrMnNiMo8-6-4 whose
 3
2.2 Selection of the parameters under consideration of parameters (the values recommended by the
machine manufacturer [10]) and the literature review,
The basis for determining the appropriate input tests were carried out to check machining stability for
parameters for the experimental tests was to determine the maximum, average and minimum levels of the
their actual values and the possible variability ranges considered parameters (Tab. 5). The roughness of the
for the adopted type of planned experiment. Input surface after machining was taken as the criterion
factors X1, X2, and X3 are respectively the wire feed value for the evaluation of machining parameters
rate, the pressure of the flushing fluid and the feed rate (Tab. 6).
of the working head. Using the recommended values

Table 5. Selection of parameters for testing

Minimum Average Maximum
No. Parameter Variable Unit
value value value
1 Wire feed rate (WS) 40 60 80 mm/min
Dielectric fluid flow
2 30 45 60 MPa
pressure (WP)
3 Head feed rate (SF) 4.5 50 5.5 mm/min

Table 6. Output quantity

No. Variable Measurement Unit

1 x Surface roughness (Ra) µm

Table 7. A list of test results.

Controlled
Test
factors on a Controlled factors on a real
No Measurement results
standardized scale
scale

WS WP SF Ra [µm]
No X1 X2 X3
[mm/min] [MPa] [mm/min] y1 y2 σ S2(y)
1 -1 -1 1 40 30 5.5 133.73 227.3 66.161 4377.28
2 1 -1 -1 80 30 4.5 55.88 108.66 37.31 1392.54
3 -1 1 -1 40 60 4.5 15.88 27 7.85 61.75
4 1 1 1 80 60 5.5 59.63 58.29 0.95 0.910
5 -1 0 0 40 45 5 120.69 179.9 41.86 1752.54
6 1 0 0 80 45 5 30.25 80.92 35.8 1283.56
7 0 -1 0 60 30 5 48.67 103.36 38.67 1495.449
8 0 1 0 60 60 5 42.97 64.68 15.34 235.56
9 0 0 -1 60 45 4.5 4.68 4.76 0.054 0.002
10 0 0 1 60 45 5.5 32.15 74.7 30.08 905.17
11 0 0 0 60 45 5 80.94 145.1 45.36 2057.65
Where:
y1 - the result of measurement in test 1
y2 - the result of measurement in test 2
σ - standard deviation
S2(y) - variance of measurement errors
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3. RESULTS
In Table 9, the mean values of actual measurements
As a result of the application of the experimental (x) and the corresponding values obtained from the
plan, it was possible to determine the main directions designated regression function (z) together with the
of generated surface roughness curves taking into square differences of these values are shown. Square
account hydromechanical parameters. The tests were differences determine the error of the mathematical
repeated three times. model developed. For additional assessment of the
After conducting the technological, metrological model, determination factor R2= 0.89 was calculated.
and statistical tests, the results can be presented as Based on the calculated indicators, i.e. Fisher's F-
in Table 7. factor and determination factor, it can be concluded
that the developed mathematical model sufficiently
3.1 Statistical model analysis reproduces the real data and can be used for further
analysis of measurement results.
The research was carried out with the assumed
level of significance α=0.05. To confirm the Table 9. Results of the regression function
repeatability of the experimental results, the value G No x z (x-z)2
of Cochran’s statistics was calculated G (α=0.05) = 1 180.5171 248.4935 4620.79251
0.3227. Since G < Gkr = 0.5715, therefore, the 2 82.273 88.6287 40.39419
conditions of the experiment should be considered as 3 21.443 -28.1575 2460.21337
reproducible. 4 58.9646 61.0913 4.52285
For the best possible adjustment of the regression 5 150.2981 189.089 1504.73382
function to actual results of the experiment, the
6 55.5866 68.139 157.56319
directional regression coefficients were analyzed
7 76.0154 108.3891 1048.05302
using the Student’s t-test. As it was revealed, the
8 53.8273 40.1989 185.73415
coefficient b22 is not significant in the calculations.
The resulting coefficients of the standardized equation 9 4.7218 9.857 26.37057
and their significance are presented in Table 8. 10 53.4259 66.531 171.74235
11 113.0247 74.294 1500.06585
Table 8. Regression coefficients
Coefficient Value Significance Based on table 9, the data obtained with
b0 74.294 significant measurements and data calculated with regression
b1 -60.475 significant function is shown in Figure 5 in the form of the
spreading diagram.
b2 -34.095 significant
b3 28.337 significant
b11 54.32 significant
Regression function (z)
b22 1.873 insignificant
Measurements (x)
b33 -36.1 significant
b12 33.941 significant
b13 -41.952 significant
b23 42.821 significant

Based on the general form of the second-degree

polynomial, for the experiment according to Hartley
and the obtained data shown in Table 9, an equation
expressing the dependence of the examined output
factor on the considered independent variables was
determined:

Ra = 74.294 - 60.475WS - 34.095WP + 28.337SF + Fig. 5. Spreading diagram (see Table 9)

54.32 WS2 - 36.1SF2 + 33.941WSWP - 41.952 WSSF
+ 42.821 3.2 Test results analysis

The Fisher-Snedecor test was used to assess the Based on the tests carried out, three-dimensional
adequacy of the designated regression equation. Value graphs determined from the second-degree polynomial
of F = 2.7159 was calculated. Since F < Fkr = 3.0123, function were developed (Fig. 6-9).
therefore, the regression equation is to be considered The influence of the head feed rate on the surface
adequate. roughness of the workpiece at the average wire feed
rate and average dielectric flushing fluid pressure is
 5
shown in Figure 10. The lowest surface roughness was erosion gap and uneven amount of energy supplied to
obtained with the minimum feed rate of the working the machining [8]. This effect can be significantly
head. When the feed rate is increased, the surface reduced by increasing the speed of wire rewinding, as
roughness increases. This results from the weakening shown in Figure 6.
of the erosion products removal efficiency from the

Fig. 6. Influence of wire rewinding speed WS and Fig. 7. Influence of wire rewinding speed WS and head
flushing fluid pressure WP on surface roughness Ra feed rate SF on surface roughness Ra at an average
at an average head feed rate flushing fluid pressure

Fig. 8. Influence of flushing fluid pressure WP and Fig. 9. Influence of flushing fluid pressure WP and
head feed rate SF on surface roughness Ra at average head feed rate SF on surface roughness Ra at
wire rewinding speed maximum wire rewinding speed

The influence of dielectric flushing fluid pressure is due to the more efficient removal of hollow products
on the surface roughness of the cut sample for average from the erosion gap [9].
values of WS and SF is shown in Figure 11. The tests The influence of wire feeding speed on the surface
show that the influence of WP on the quality of the roughness of the workpiece with average parameters
machined surface is relatively low. The lowest WP and SF is shown in Figure 12. In this case, there is
roughness was obtained for the highest pressure. This a linear relationship, i.e. the higher the wire feeding
speed, the lower the roughness of the surfaces of the
6
cut parts. This is due to the improvement of the erosion 2. The effect of dielectric flushing fluid pressure on
products removal efficiency and the reduction of the the resultant factor is relatively small. It only gains
working electrode wear effect, which directly affects in importance in the case of a low working head
the quality of the machined surface. feed rate. In this situation a reduction in flushing
fluid pressure causes a significant increase in
roughness. This is due to poor drainage of
120 machining products from the erosion gap.
Surface roughness [µm]

100 3. The smallest surface roughness of the cut samples

80 was obtained at the minimum working head feed
60 rate, maximum wire feed rate, and maximum
40 dielectric flushing fluid pressure.
20 4. It is advisable to conduct future studies on the
0 influence of other operating parameters of WEDM
4.5 5 5.5 machines, such as electric current and the duration
Working head feed rate [mm/min]] of the electric discharge pulse on selected quality
and economic characteristics.
Fig. 10. Influence of the working head feed rate on the The conducted research may constitute the basis
surface roughness of the workpiece for optimization of the electro-erosion cutting process,
which can significantly improve the quality and
120 economic conditions of machining, applicable in many
Surface roughness [µm]

100
industries.
80
5. REFERENCES
60
40 1. Scott D., Boyina S., Analysis and optimization of
20 parameter combinations in wire electrical discharge
0
machining. International Journal of Production
30 45 60
Research. 1990.
Dielectric flushing fluid pressure [Mpa]
2. Świercz R., Oniszczuk-Świercz D., Wpływ
Fig. 11. Influence of dielectric flushing fluid pressure on parametrów obróbki elektroerozyjnej na właściwości
the surface roughness of the workpiece użytkowe stali o wysokiej przewodności cieplnej. 2014,
1, pp. 29-33.
200 3. K. L. Meena A. Manna,S. S. Banwait, Jaswanti.,
Surface roughness [µm]

150
Effect of wire feed rate and wire tension during
machining of pr-al-sic-mmc,s by wedm. European
100 Journal of Engineering and Technology. 2013.
50 4. Rozenek M, Dąbrowski, L., Aspekty ekonomiczne i
dokładnościowe wycinania elektroerozyjnego.
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5.Korzyński M., Metodyka eksperymentu,
Fig. 12. Influence of the wire feeding speed on the surface Wydawnictwo Naukowe PWN, 2017
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4. CONCLUSIONS in sliding contact of satelite gears of a hydraulic
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the conducted tests, the following conclusions were Technologiczne. Tom II, Kraków: Firma Naukowo-
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roughness of the cut parts has the wire feeding sterowania wycinarką drutową LN1W, Nakamachidai,
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