Title: Optimisation and experimental analysis of response parameters in a gear cutting process of ultrasonic assisted wire EDM

Authors: Kasinath Das Mohapatra; Subrat Kumar Bhuyan; Pradyut Kumar Swain; Mantra Prasad Satpathy; Rudra Narayan Kandi; Ananda Kumar Sahoo; Susanta Kumar Sahoo

Addresses: Department of Mechanical Engineering, College of Engineering and Technology, Bhubaneswar – 751019, Odisha, India ' G.H. Raisoni Institute of Engineering and Technology, Pune – 440016, Maharastra, India ' Department of Mechanical Engineering, Aryan Institute of Engineering and Technology, Bhubaneswar – 752050, Odisha, India ' Department of Mechanical Engineering, KIIT Deemed to be University, Bhubaneswar – 751024, Odisha, India ' Department of Mechanical Engineering, IIT Delhi, Delhi – 110016, India ' Department of Mechanical Engineering, NIT Rourkela, Rourkela – 751019, Odisha, India ' Department of Mechanical Engineering, NIT Rourkela, Rourkela – 751019, Odisha, India

Abstract: The current work deals with a new technique of ultrasonic-assisted wire electric discharge machining (WEDM) in a gear machining operation of titanium alloy. An effort has been made to couple the ultrasonic vibration to the wire EDM in order to compare and investigate the effects of different response parameters with that of conventional WEDM. The responses are optimised by using technique for order of preference by similarity to ideal solution (TOPSIS) methodology. Further, the microstructural analysis has been performed at the optimal setting of ultrasonic assisted WEDM for both material and the wire electrode. The output responses obtained at the optimal settings are also compared for both conventional WEDM and ultrasonic assisted WEDM (WEDM + UV) in machining of gear cutting operation. It is observed that the ultrasonic assisted wire EDM gives better machining results than conventional WEDM while machining of the gears as far as machining rate (MRR) is concerned.

Keywords: WEDM; wire electric discharge machining; gear; ultrasonic; TOPSIS; technique for order of preference by similarity to ideal solution; MRR; machining rate; vibration; wire; electrode; conventional; titanium.

DOI: 10.1504/IJMMS.2021.121247

International Journal of Mechatronics and Manufacturing Systems, 2021 Vol.14 No.3/4, pp.202 - 227

Received: 15 Apr 2021
Accepted: 24 Jun 2021
Published online: 01 Mar 2022 *

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