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The photovoltaic sector needs a high-throughput slicing method that produces minimal waste to meet rising demand. Wire electric discharge machining (WEDM) has emerged as an alternative slicing method in recent research efforts. Polycrystalline silicon is sliced using the WEDM process with a zinc-coated electrode of Ø0.25 mm in diameter. Experiments were planned and conducted according to Box Behnken’s design of experiments. As inputs, seven different process parameters were used: pulse on time (PONT), pulse off time (POFFT), peak current (PC), spark gap voltage (SGV), wire feed (WF), wire tension (WT), and water pressure (WP). Response parameters measured were cutting speed (CS), surface roughness (SR), and kerf width (KW). Various process parameters have also been analyzed with ANOVA methods for predictive modeling. Based on experimental data, this study determines the appropriate optimal solutions via desirability functions. During the WEDM process, the PONT, POFFT, PC, and SGV significantly influence the discharge energy on the sliced surface. As a result of this study, CS of 0.78 mm2/min, SR of 2.87 μm, and KW of 0.70 mm were observed at the optimal settings of PONT of 119 μs, POFFT of 42 μs, PC of 38A, SGV of 36V, WF of 3 mm/min, WT of 2 kg and WP of 6 kg/cm2. Surface morphology was determined using scanning electron microscope and Energy dispersive X-ray to investigate the surface characteristics.

CP-Ti G2 has become the preferred biocompatible material for various devices mainly used in orthopedic and dental implants and it is also used in aviation and aircraft. While CP-Ti G2 deals with good ductility, higher stiffness, and fatigue resistance. The novelty of present research work was attentive to the effect of WEDM factors on MRR. After machining, surface topography was examined through SEM. MRR was modeled through ANOVA to analyze the adequacy. It was observed that POT, POFT, PC, and SGV most significant factors. The WEDM factors have also been significantly deteriorating the morphology of machined samples in the form of craters, debris, and micro cracks. A multi-objective optimization ‘desirability’ function hybrid with a supervised machine learning algorithm was applied to obtain the optimal solutions. The results show a good agreement between actual and predicted values.

WEDM process is usually used in manufacturing industries to machine electrically conductive materials with complex shapes and varying degree of hardness. This study mainly involves the development of empirical models for wire wear ratio and material removal rate, in terms of six prominent input parameters using response surface methodology. The objective of developing the model is to establish the quantitative relationship between the output and the input control parameters. The effect of significant terms on machined work surface and wear out wire surface topography was analyzed through energy dispersive X-ray analysis and scanning electron microscope techniques. The wire and machined surface topography was deteriorated and appeared in the form of craters, spherical particles, globules of debris and micro-cracks. [ABSTRACT FROM AUTHOR]

In this work, quantitative assessment of surface damage in terms of parameters like surface crack density and recast layer thickness in wire electrical discharge machining (WEDM) process has been undertaken. The effect of processing conditions on crack formation is studied using scanning electron microscope. Surface crack density and recast layer thickness analysis in terms of machining parameters such as pulse on time, pulse off time, peak current, spark gap voltage significantly deteriorate the microstructure of machined samples, which produces the deeper, wider overlapping craters, pockmarks, globules of debris andmicro cracks. The microstructure analysis ofWEDMsurface was based upon the theory of electrical discharge phase and metallurgical physics. It is found that the pulse on time, pulse off time and peak current are the most dominating parameters for both surface crack density and recast layer thickness. [ABSTRACT FROM AUTHOR]

The wire electric discharge machining process is an alternative for machining of the high strength temperature resistant materials. The present research work is mainly focused on the investigation of integrity of the work surface and wire electrode surface after machining with WEDM. Experimental results showed that pulse-on time, pulse-off time and peak current significantly affected the surface integrity with the formation of deep-wide overlapping craters, pock marks, debris, micro-cracks and recast layer. Both carbides and oxides were formed either in free form and/or in compound form due to decomposition of de-ionized water, machined samples and wire material. The compounds like titanium dioxide (rutile)(TiO2),(TiO0.325),Ti2O3, Ilmenite(Fe2Ti4O), titanium carbides(TiC)and copper titanium dioxide(Cu3TiO4)were formed due to phase transformations that were analyzed through X-ray diffraction and energy dispersive X-ray method. The effect of process parameters on the wear of wire surface has also been considered. [ABSTRACT FROM AUTHOR]