Conventional machining of electrically conductive high hardness materials poses challenging issues in machine tool industry. This gave rise to the development of hybrid non - conventional machining processes. Wire electrical discharge hybrid turning (WEDHT) is a novel hybrid process for both macro and micro level cylindrical components of complicated shape and size. WEDHT combines wire electrical discharge machining (WEDM) and turning operation as single operation. The WEDHT process is influenced by the many input parameters like discharge voltage, discharge current, pulse-on time, pulse-off time, spark gap and non-electrical parameters such as type of dielectrics, flushing pressure, workpiece rotational speed, wire feed etc. Hence the selection of best parameter levels in WEDHT is a complex and challenging decision without complete process understanding. This review article focused on detailed study of parametric effects on material removal rate, surface finish, roundness, recast layer and crater formation are carried out. Finally, the future directions of WEDT hybrid process is highlighted. © 2017 Elsevier Ltd. All rights reserved.

Vignesh M

Department of Manufacturing Engineering

School of Mechanical Engineering

Vellore Campus

Ramanujam R

Kuppan P

Vellore Institute of Technology (VIT) is a private university located in&nbsp;Tamil Nadu, India. Founded in 1984, as Vellore Engineering College, the institution offers 20 undergraduate, 34 postgraduate, four integrated and four research programs. It has campuses in Vellore, Amravati, Bhopal and Chennai.

VIT is one of the top ranked private universities in India according to NIRF, THE and QS Rankings.&nbsp;Govt. of India has recognized&nbsp;VIT, Vellore as an&nbsp;Institution of Eminence. This has allowed VIT to take independent quality initiatives and move up in world ranking.

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VIT University

Materials Today: Proceedings

Energy conservation is one of the most important aspects of electrical discharge machining process in which the material removal is by means of spark erosion. Metal removal in wire electrical discharge turning is a complex erosion mechanism which involves melting, vaporization and rapid cooling of molten material. In this work, the significance of discharge energy on the performance of wire electrical discharge turning process, namely, material removal rate, surface finish, thickness of recast layer and surface crack, is analyzed. New model to estimate material removal rate and surface finish in wire electrical discharge turning process have been proposed. Erosion energy and kinetic energy imparted by electrons and average physio-thermal properties of work material are utilized for the modeling. Proposed models are validated by conducting experiments on AISI 4340 steel material. The results obtained from the model are well in agreement with the experimental values. The influence of discharge energy on surface crack and recast layer thickness is analyzed using scanning electron microscope micrographs and energy-dispersive x-ray spectroscopy analysis. Surface crack is observed at higher discharge energy. The thickness of recast layer increases with the increase in discharge energy. Three-dimensional surface topography reveals the turbulent nature of machining process resulted from transient erosion phenomena of wire electrical discharge turning process. Higher material removal rates of the order of about 0.06 g/min with consistent average roughness in the range of 4.5-5.5 μm at the expense of 1.6-2.6 J of discharge energy are achieved in this work. The proposed models can be utilized for machining of difficult to machine material by effective utilization of energy that leads to energy conservation in wire electrical discharge turning process. © 2015 Institution of Mechanical Engineers.

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

Analysis on the effect of discharge energy on machining characteristics of wire electrical discharge turning process

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Journal of Materials Processing Technology

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Journal of Manufacturing Processes

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A Comprehensive Review on Wire Electrical Discharge Based Hybrid Turning (WEDHT)

Journal	Data powered by TypesetMaterials Today: Proceedings
Publisher	Data powered by TypesetElsevier BV
ISSN	2214-7853
Open Access	No