appendix- i specifications of machines and measuring instruments a1: configuration...

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APPENDICES

APPENDIX- I Specifications of Machines and Measuring Instruments

A1: Configuration and Specifications of WEDM Machine

Figure A1 Wire Electrical Discharge Machine Used for Experimentation

Specifications of WEDM Machine Model : Robofil 290 Dimensions : 1800mm x 1600mm x 2125mm Maximum Workpiece Weight : 550kg Machining Stroke (X x Y x Z ) : 399mm x 249mm x 200mm Wire Diameters : 0.10 - 0.30mm Wire Spool Size : 6Kg Taper Capacity : 0 to 30 Degrees Network Frequency : 50HZ Dielectric Tank Capacity : 300Ltrs. Machine Weight : 2190Kg.

Control panel

Machining area

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A2: Configuration and Specifications of Cryogenic Treatment Setup

/

Figure A2 Cryogenic Processor for Cryogenic Treatment of Brass Wires

Specifications of Cryogenic Processor Make : Primero Model : CP220LH Nitrogen Cylinder Make : Taylor Wharton Model : XL 240/FB Pressure : 13.8bar

A3: Measuring Instruments

1. Surf Tester SJ 201

For the measurement of roughness of work piece surfaces after machining, a Surf

tester SJ201 was used. The stylus method was employed for the measurement of

surface roughness. Following are the main specifications:

Make and Model : Mitutoyo, SJ 201 Measuring Range : 350µm Stylus Material : Diamond Tip Radius : 5 µm Measuring Force : 4mN Cut-off Length (mm) : 0.08, 0.25, 0.8, 2.5 Evaluation Length (mm) : 0.4, 1.25, 4, 12.5 Standard : JIS B0601-1994

Chamber for

cryogenic

treatment of

brass wire

spool

176

2. Micro-Hardness Tester

Micro viker hardness tester (Fig. A4) was used for the measurement of surface micro-

hardness of wire electrode before and after cryogenic treatment. It had the following

specifications:

Make and Model : Akasi, MVK-H2 Load Range : 50,100,300,500gm&1kg Resolution : 0.001mm Indenter : Diamond pyramid Load Duration Time : 5 to 999sec.

Figure A4 Micro Viker Hardness Tester

3. Scanning Electron Microscope (SEM)

For taking scanning electron micrographs, a SEM machine (Fig. A5) with following

specifications was employed.

Make and Model : JEOL, JSM-6610LV Detector : Everhart- Thornley Magnification : 5-300000(149steps) Working Distance : 5-48 mm Filament : Precentred tungsten

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Figure A5 Scanning Electron Microscope (SEM) Setup

4. Weighing Scale

A precision weighing scale was used for checking the weight of wire electrode before

and after machining. It had the following specifications.

Make and Model : Citizen, CV 220 Least Count : 0.1mg Max Weight Capacity : 220gm

Figure A6 Precision Weighing Scale

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APPENDIX-II Performance Measures for Experimental Trial Conditions

Table B1 Performance Measures (MRR, SR) for Pulse Width

Pulse Width (µm)

UTWE SCTWE DCTWE Fixed Parameters

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

0.2 12.12 2.13 15.22 2.10 17.00 2.10 B -10 µs , WS - 9.0 m/min WT - 1.40 daN IAL -12 A S - 20 mm/min, Aj -36 V Tac -0.2 µs Inj -4 bar V - (-80)

0.4 24.20 2.38 27.80 2.20 29.00 2.10 0.7 39.15 2.55 40.12 2.30 42.50 2.20 1.0 45.05 3.21 48.06 3.00 51.94 3.00 1.2 52.15 3.20 56.10 2.98 56.76 2.98 1.4 49.21 3.35 55.15 3.10 55.73 3.00

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B2 Performance Measures (MRR & SR) for Time between Two Pulses

Time between

two pulses


MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

4 52.10 2.72 58.10 2.65 60.02 2.62 A -1 µs , WS -9.0 m/min WT -1.40 daN IAL -12 A S - 20 mm/min, Aj -36 V Tac -0.2 µs Inj -4 bar V - (-80)

8 40.51 2.38 43.00 2.21 48.23 2.23 12 31.53 1.95 36.05 1.87 37.10 1.82 16 29.70 1.81 30.12 1.81 31.09 1.75 20 18.90 1.62 20.50 1.42 22.50 1.37 24 18.91 1.60 20.50 1.53 22.51 1.43

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B3 Performance Measures (MRR & SR) for Wire Tension

Wire Tension


MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

0.4 34.22 2.42 36.91 2.41 37.00 2.38 A -1 µs B -10 µs , WS - 9.0 m/min IAL -12 A S - 20 mm/min, Aj -36 V Tac -0.2 µs Inj -4 bar V - -80

0.9 35.91 2.51 38.23 2.39 38.50 2.31 1.4 38.09 2.63 42.51 2.49 43.12 2.41 1.9 38.02 2.62 41.00 2.36 42.11 2.35 2.4 37.00 2.51 38.21 2.45 38.03 2.40 UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width, B-Time between two pulses, WS- Wire feed speed, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

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Table B4 Performance Measures (MRR&SR) for Wire Feed

Wire feed


MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

4 37.51 2.51 38.90 2.45 39.92 2.49 A - 1 µs B -10 µs , WT - 1.40 daN IAL - 12 A S - 20 mm/min, Aj - 36 V Tac - 0.2 µs Inj - 4 bar V - -80

6 37.21 2.42 39.61 2.36 40.60 2.35 9 37.63 2.49 39.92 2.39 40.31 2.45 12 37.67 2.40 40.92 2.38 40.52 2.35 14 38.71 2.41 41.24 2.38 41.41 2.32

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width, B-Time between two pulses, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B5 Performance Measures (MRR&SR) for Wire Feed Rate

Feed Rate


MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

5 35.91 2.52 37.72 2.41 38.55 2.51 A - 1 µs B - 10 µs , WS - 9.0 WT - 1.40 daN IAL - 12 A Aj -36 Tac - 0.2 µs Inj - 4 V - -80

10 36.22 2.65 38.80 2.65 40.85 2.61 20 36.52 2.75 38.90 2.62 40.84 2.55 40 36.60 2.81 39.72 2.52 40.82 2.42

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width, B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B6 Performance Measures (MRR&SR) for Servo Reference Mean Voltage

Servo Reference Mean Voltage


MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

MRR (mm3/min)

SR (µm)

12 50.11 3.41 54.22 3.21 56.11 3.15 A - 1 µs B -10 µs , WS - 9.0 m/min WT - 1.40 daN

IAL - 12 A S - 20 mm/min, Tac - 0.2 µs Inj - 4bar V - (-80)

24 40.31 3.25 44.00 3.00 44.00 2.95 36 38.00 2.58 39.51 2.47 40.03 2.36 48 32.03 1.92 34.21 1.65 35.00 1.51 60 28.02 1.51 29.00 1.51 30.00 1.31

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width, B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

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Table B7 Performance Measure (DV) for Pulse Width

Pulse Width (µm)


Dimensional Variation (%)



0.2 0.0323 0.0321 0.0319 A - 1 µs B -10 µs , WS - 9.0 m/min WT - 1.40 daN IAL -12 A S - 20 mm/min, Aj -36 V Tac -0.2 µs Inj -4 bar V - (-80)

0.4 0.0398 0.0387 0.0384 0.7 0.0425 0.0419 0.0412 1.0 0.0418 0.0404 0.0401 1.2 0.0409 0.0402 0.0410 1.4 0.0402 0.0397 0.0382

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B8 Performance Measure (DV) for Time between Two Pulses

Time between two pulses





4 0.0383 0.0380 0.0380 A - 1 µs B -10 µs , WS - 9.0 m/min WT - 1.40 daN IAL -12 A S - 20 mm/min, Aj -36 V Tac -0.2 µs Inj -4 bar V - (-80)

8 0.0378 0.0368 0.0368 12 0.0392 0.0382 0.0381 16 0.0375 0.0367 0.0362 20 0.0371 0.0359 0.0339 24 0.0365 0.0351 0.0345

UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B9 Performance Measure (DV) for Wire Tension

Wire Tension





0.4 0.0313 0.0311 0.0303 A - 1 µs B -10 µs , WS - 9.0 m/min WT - 1.40 daN IAL -12 A S - 20 mm/min, Aj -36 V Tac -0.2 µs Inj -4 bar V - (-80)

d 0.0328 0.032 0.0338 1.4 0.0355 0.0343 0.0355 1.9 0.0352 0.0328 0.0332 2.4 0.0352 0.0322 0.0332 UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

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Table B10 Performance Measure (DV) for Wire Feed

Wire feed UTWE SCTWE DCTWE Fixed Parameters




4 0.0325 0.0320 0.0317 A - 1 µs B - 10 µs , WS - 9.0 m/min WT - 1.40 daN IAL - 12 A S - 20 mm/min, Aj - 36 V Tac - 0.2 µs Inj - 4 bar V - (-80)

6 0.0315 0.0312 0.0310 9 0.0315 0.0310 0.0307 12 0.0312 0.0304 0.0301 14 0.0313 0.0324 0.0321 UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B11 Performance Measure (DV) for Wire Feed Rate

Feed Rate UTWE SCTWE DCTWE Fixed Parameters





10 0.0352 0.0342 0.0341 20 0.0352 0.0342 0.0343 40 0.0353 0.0341 0.0342 UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

Table B 12 Performance Measure (DV) for Servo Reference Mean Voltage

Servo Reference Mean Voltage






24 0.0415 0.0410 0.0410 36 0.0401 0.0389 0.0385 48 0.0405 0.0395 0.0390 60 0.0395 0.0387 0.0380 UTWE- Untreated wire electrode, SCTWE- Shallow cryogenic treated wire electrode, DCTWE- Deep cryogenic treated wire electrode A-Pulse width B-Time between two pulses, WS- Wire feed speed, WT- Wire tension, IAL- Ignition pulse current, S- Max feed rate, Aj – Servo reference mean voltage, Tac- Short pulse time, Inj- Injection pressure(dielectric), V- Cutting voltage

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Appendix-III Average and Delta values of Main and S/N Data

Table C1 Average and Delta Effects- Main Data (MRR)

Parameter Designation

Average values, MRR (mm3/min) Delta, MRR (mm3/min) L1 L2 L3

A 39.76 47.83 8.07 B 26.15 49.56 55.67 29.52 C 47.74 46.97 36.66 11.08 D 46.98 39.86 44.54 7.11 E 42.59 43.85 44.93 2.34

L1, L2 and L3 represents average value of main data of corresponding parameters at levels 1, 2 and 3 respectively. Delta is the Difference between the highest and lowest values for each response characteristic to measure the size of the effect. A-Type of wire, B- Pulse width, C- Time between two pulses, D- Wire tension, E- Servo reference mean voltage.

Table C2 Average and Delta Effects - S/N Data (MRR)


Average values, MRR(mm3/min) Delta, MRR(mm3/min) L1 L2 L3

A 31.24 32.97 1.73 B 27.66 33.85 34.81 7.15 C 33.29 32.97 30.07 3.23 D 33.19 31.14 31.99 12.05 E 32.46 31.81 32.05 0.66

Table C3 Average and Delta Effects - Main Data (SR)


Average values, SR (µm) Delta,, SR(µm) L1 L2 L3

A 2.792 2.509 0.283 B 2.252 2.670 3.030 0.778 C 2.728 2.752 2.472 0.280 D 2.658 2.582 2.712 0.130 E 2.745 2.573 2.633 0.172


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Table C4 Average and Delta Effects - S/N Data (SR))

Parameter

Designation Average values, SR (µm) Delta,, SR(µm)

L1 L2 L3 A -8.818 -7.890 0.928 B -7.009 -8.434 -9.619 2.610 C -8.667 -8.728 -7.667 1.060 D -8.387 -8.140 -8.536 0.397 E -8.723 -8.040 -8.300 0.683

Table C5 Average and Delta Effects - Main Data (WWR)

Parameter

Designation Average values, WWR Delta,, WWR

L1 L2 L3 A 0.04644 0.04222 0.00422 B 0.03167 0.04767 0.05367 0.02200 C 0.04833 0.04900 0.03567 0.01333 D 0.04767 0.04050 0.04483 0.00717 E 0.04417 0.04400 0.04483 0.00083


Table C6 Average and Delta Effects - S/N Data (WWR)

Parameter

Designation Average values, WWR Delta, WWR

L1 L2 L3 A 27.05 28.01 0.96 B 30.59 26.49 25.51 5.08 C 26.38 26.46 29.76 3.38 D 26.59 28.49 27.51 1.90 E 27.14 27.99 27.46 0.85

Table C7 Average and Delta Effects - Main Data (MRR)



A 39.76 46.00 6.24 B 25.66 47.90 55.07 29.40 C 46.67 45.86 36.10 10.57 D 46.36 38.86 43.42 7.50 E 41.61 43.23 43.80 2.20


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Table C8 Average and Delta Effects - S/N Data (MRR)

Parameter

Designation Average values, MRR(mm3/min) Delta, MRR(mm3/min)

L1 L2 L3 A 31.24 32.61 1.37 B 27.48 33.57 34.72 7.24 C 33.12 32.77 29.89 3.23 D 33.09 30.91 31.78 2.17 E 32.28 31.63 31.87 0.65

Table C9 Average and Delta Effects- Main Data (SR)


Average values, SR (µm) Delta, SR (µm) L1 L2 L3

A 2.792 2.348 0.444 B 2.160 2.595 2.955 0.795 C 2.630 2.673 2.407 0.267 D 2.583 2.490 2.637 0.147 E 2.675 2.517 2.518 0.158


Table C10 Average and Delta Effects - S/N Data (SR))

Parameter

Designation Average values, SR (µm) Delta, SR (µm)

L1 L2 L3

A -8.818 -7.301 1.517 B -6.638 -8.149 -9.392 2.755 C -8.308 -8.468 -7.403 1.064 D -8.122 -7.787 -8.270 0.483 E -8.478 -7.808 -7.893 0.670

Table C11 Average and Delta Effects - Main Data (WWR)


Average values, WWR Delta, WWR L1 L2 L3

A 0.04644 0.03778 0.00867 B 0.02933 0.04533 0.05167 0.02233 C 0.04617 0.04717 0.03300 0.01417 D 0.04533 0.03850 0.04250 0.00683 E 0.04217 0.04117 0.04300 0.00183


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Table C12 Average and Delta Effects S/N Data (WWR)

Parameter

Designation Average values, WWR Delta, WWR

L1 L2 L3 A 27.05 29.23 2.18 B 31.55 27.00 25.87 5.68 C 26.82 26.84 30.77 3.96 D 27.12 29.30 28.01 2.19 E 27.59 29.01 27.83 1.42

Table C13 Average and Delta Effects - Main Data (Utility Data, Group -I)



A 4.694 5.878 1.183 B 4.892 5.677 5.290 0.785 C 5.358 5.228 5.272 0.130 D 5.487 5.215 5.157 0.330 E 5.170 5.407 5.282 0.237


Table C14 Average and Delta Effects - S/N Data (Utility Data, Group-I)


Average values, MRR(mm3/min) Delta, MRR(mm3/min) L1 L2 L3

A 13.41 15.35 1.94 B 13.72 14.98 14.44 1.25 C 14.51 14.32 14.30 0.21 D 14.70 14.26 14.17 0.53 E 14.21 14.55 14.37 0.30

Table C15 Average and Delta Effects - Main Data (Utility Data, Group -II)


Average values, SR (µm) Delta, SR (µm) L1 L2 L3

A 4.642 6.134 1.492 B 5.030 5.737 5.398 0.707 C 5.478 5.293 5.393 0.185 D 5.600 5.343 5.222 0.378 E 5.237 5.537 5.392 0.300


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Table C16 Average and Delta Effects- S/N Data (Utility Data, GROUP –II)

Parameter

Designation Average values, SR (µm) Delta, SR (µm)

L1 L2 L3 A 13.31 15.73 2.42 B 13.91 15.04 14.60 1.14 C 14.68 14.41 14.46 0.27 D 14.85 14.45 14.25 0.61 E 14.30 14.73 14.51 0.43

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APPENDIX- IV Machined Workpieces, Wire Electrode Spools with Fixture

Assembly, Workpiece Material Properties

D1: Workpieces

Figure D1 Sample Workpieces after WEDM

D2: Brass Wire Spools

Figure D2 Fixture Assembly for one Brass Wire Spool (a) and three Brass Wire Spools (b).

Table D1 Properties of EN-31 (AISI52100) Die Steel

Property Value Density 7860kg/m3

Young’s modulus, E 201GN/m2

Melting temperature, Tm 1777K Reference temperature, To 300K Poisson’s ratio, υ 0.27 Max. yield strength, Syield 3203MPa Latent heat for phase change-melting, Lm 2688KJ/Kg Latent heat for phase change-evaporation, Lv 1586KJ/Kg

a b

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APPENDIX-V Orthogonal Array and XRD Graphs

E 1: L18 Orthogonal Array Graphs

Figure E1: Linear Graphs for L18 Orthogonal Array

E 2: XRD Graphs

Figure E2 XRD Graph of Untreated Brass Wire Electrode

Figure E3 XRD Graph of Shallow Cryogenic Treated Brass Wire Electrod

1 2

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Figure E3 XRD Graph of Deep Cryogenic Treated Brass Wire Electrode

appendix- i specifications of machines and measuring instruments a1: configuration...

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