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NH N CH NG B M N B A STUDY OF THE EFFECTS OF MACHINING PARAMETERS ON SURFACE QUALITY AND COSTS WITH HIGH-THICKNESS OF WORKPIECE USING WIRE-CUT EDM K Thu : 8520103 LU TP H -HCM PGS.TS NGUY N H U L C - Ch t ch h - TS TR N H I NAM - Ph n bi n TS NGUY N H U TH - Ph n bi n - ng - - MSHV: 1870323 A study of the effects of machining parameters on surface quality and costs with high-thickness of workpiece using wire-cut edm - u t ng quan v - nv tv u p ng c v nt i gian ng - Thi t k - Ti - II n c c d ng i gian n ch m m li u th c nghi nm 22/02/2021 : 13/06/2021 li ( ABSTRACT Wire Electrical Discharge Machining (WEDM) is one of the advanced machining techniques that are widely used today This technique can machine numerous components with high hardness as well as parts with complex shapes that conventional machining can not perform At the same time it improves high quality and precision This thesis was conducted to optimize the accuracy, surface quality and cost with a thickness of 120 mm on 2083 plastic injection mold material by using EDM The full factorial design of experiments was used to study the effect of variables such as wire speed, wire tension, pulse discharge Time On, and pulse discharge Time Off on accuracy, surface quality, and cost when machining on a Sodick VZ300L wire cutting machine Minitab data analysis software is used to generate regression and optimization equations i iv vi .1 .2 .10 10 .11 ed) 11 12 -ON) 13 -OFF) 14 14 .14 15 15 - 1870323 15 15 .17 .17 .17 19 .19 .20 22 22 22 24 25 26 27 33 39 39 .42 46 48 49 50 4.3 51 - 1870323 53 .53 55 56 - 1870323 4.3 ng c 4.1 4.2 - 1870323 Ta) 46 4.3 O) 4.4 m) 4.1- 4.4 - [26] - 1870323 47 4.3.1 - g (T- 4.9 =0,05), T- 4.9 Source Model Linear T-ON T-OFF WS WT 2-Way Interactions T-ON*T-OFF T-ON*WS T-ON*WT T-OFF*WS T-OFF*WT WS*WT Error Total Model Summary S R-sq 0.330647 90.98% DF 10 1 1 1 1 1 16 R-sq(adj) 75.94% Adj SS 6.61539 5.95301 5.90004 0.01030 0.02250 0.02016 0.66239 0.44689 0.06970 0.09986 0.00133 0.00093 0.04368 0.65596 7.27136 Adj MS 0.66154 1.48825 5.90004 0.01030 0.02250 0.02016 0.11040 0.44689 0.06970 0.09986 0.00133 0.00093 0.04368 0.10933 F-Value 6.05 13.61 53.97 0.09 0.21 0.18 1.01 4.09 0.64 0.91 0.01 0.01 0.40 P-Value 0.019 0.004 0.000 0.769 0.666 0.683 0.495 0.090 0.455 0.376 0.916 0.930 0.551 R-sq(pred) 50.62% 4.5 4.9 - 1870323 - 48 - - - ng - - - 4.5 4.3.2 4.10 T- =0,05), T-ON, -value > 0,05), -ON, T-OFF, - 1870323 49 4.10 Source Model Linear T-ON T-OFF WS WT 2-Way Interactions T-ON*T-OFF T-ON*WS T-ON*WT T-OFF*WS T-OFF*WT WS*WT Error Total DF 10 1 1 1 1 1 16 Adj SS 0.000141 0.000112 0.000049 0.000001 0.000006 0.000056 0.000028 0.000001 0.000000 0.000020 0.000000 0.000002 0.000004 0.000065 0.000206 Model Summary S R-sq R-sq(adj) 0.0032981 68.28% 15.42% Adj MS 0.000014 0.000028 0.000049 0.000001 0.000006 0.000056 0.000005 0.000001 0.000000 0.000020 0.000000 0.000002 0.000004 0.000011 F-Value 1.29 2.59 4.50 0.09 0.57 5.17 0.43 0.09 0.02 1.86 0.02 0.21 0.37 P-Value 0.392 0.143 0.078 0.772 0.477 0.063 0.837 0.772 0.884 0.221 0.884 0.665 0.566 R-sq(pred) 0.00% 4.3.3 4.11 -value = 0,034 < -ON, T- -value > 4.11 Source Model Linear T-ON T-OFF WS WT 2-Way Interactions T-ON*T-OFF DF 10 1 1 - 1870323 Adj SS 0.000097 0.000050 0.000003 0.000002 0.000000 0.000046 0.000047 0.000018 Adj MS 0.000010 0.000013 0.000003 0.000002 0.000000 0.000046 0.000008 0.000018 F-Value 1.59 2.05 0.50 0.26 0.01 7.44 1.28 2.95 P-Value 0.296 0.206 0.506 0.632 0.923 0.034 0.388 0.137 50 T-ON*WS T-ON*WT T-OFF*WS T-OFF*WT WS*WT Error Total 1 1 16 Model Summary S R-sq 0.0024751 72.55% 0.000001 0.000005 0.000023 0.000001 0.000000 0.000037 0.000134 0.000001 0.000005 0.000023 0.000001 0.000000 0.000006 0.09 0.83 3.68 0.09 0.01 R-sq(adj) R-sq(pred) 26.79% 0.00% 4.6 - > 0,05 ( 0.772 0.398 0.103 0.772 0.923 -value 4.11 - 4.6 4.3.4 Kh 4.12 xung (T- -value = 0,009 < 0,05), -value > - 1870323 51 4.12 Source Model Linear T-ON T-OFF WS WT 2-Way Interactions T-ON*T-OFF T-ON*WS T-ON*WT T-OFF*WS T-OFF*WT WS*WT Error Total Model Summary S R-sq 67.7582 85.75% DF Adj SS 10 165700 144100 65025 65025 11025 3025 21600 8100 400 2500 1600 900 8100 27547 16 193247 R-sq(adj) 61.99% Adj MS 16570.0 36025.0 65025.0 65025.0 11025.0 3025.0 3600.0 8100.0 400.0 2500.0 1600.0 900.0 8100.0 4591.2 F-Value 3.61 7.85 14.16 14.16 2.40 0.66 0.78 1.76 0.09 0.54 0.35 0.20 1.76 P-Value 0.065 0.015 0.009 0.009 0.172 0.448 0.612 0.232 0.778 0.488 0.577 0.673 0.232 R-sq(pred) 0.00% 4.7 -value > 0,05 ( 4.12 - - - T- - i gian T- - 1870323 52 4.7 4.3.5 i quy -ON (X1), T-OFF i quy d ut nh Y1 = 3,0294 + 0,6072.X1 i quy d ut Y3 = 0,007647 i quy d (4.1) 0,001687.X4 ut (4.2) n kh ng : Y4 = 921,8 63,8.X1 + 63,8.X2 (4.3) 4.3.6 T - 1870323 53 4.8 T-ON = s , T-OFF = s, WS = 160 m , Ta = 0,015mm , 4.8 - 1870323 54 K T LU N - - - - -ON, T- T- -ON = s , T-OFF = s, WS = 160 m , Ta = 0,015mm , O = 0,012mm, m = 879,26 0,02 mm - 1870323 55 [1] : Nxb [2] -420HS, - 37, 2018 [3] CW420 HS, -44, 2018 [4] - Vcme 2018, 2018 [5] K Kanlayasiri "Effects of wire-EDM machining variables on surface roughness of newly developed DC 53 die steel: Design of experiments and regression model," J Mater Process, vol 192-193, pp 459 464, 2007 [6] A Shah J Mater Eng Perform, vol 20, pp 71-76, 2011 [7] Abdulkareem, "Experimental Investigation of Machining Parameters on Surface Roughness in Dry and Wet Wire-Electrical Discharge Machining," Advanced Materials Research, vol 264-265, pp 831-836, 2011 [8] R P Srinivasa M Parameters for Surface Roughness, MRR and White Layer in Machining of ScienceDirect, vol 5, pp 2197-2206, 2014 [9] Pramanik "Accuracy and finish during wire electric discharge machining of metal matrix composites for different reinforcement size and machining conditions," Proc Inst Mech Eng B J Eng Manuf, vol 232, p 1068 1078, 2016 - 1870323 56 o [10] M S Rao and N Venkaiah, "Experimental investigations on surface integrity issues of Inconel-690 during wire-cut electrical discharge machining process," Proc Inst Mech Eng B J Eng Manuf, vol 232, no 4, pp 731-741, 2016 [11] Singh "An experimental investigation on machining parameters of AISI D2 steel using WEDM," Int J Adv Manuf Technol, vol 93, pp 203-214, 2017 [12] C Camposeco-Negrete, "Prediction and optimization of machining time and surface roughness of AISI O1 tool steel in wire-cut EDM using robust design and desirability approach," The International Journal of Advanced Manufacturing Technology, vol 103, pp 2411 2422, 2019 [13] E Sonia "Recycled Ti-17 Based Composite Design; Optimization Process Parameters in Wire Cut Electrical Discharge Machining (WEDM)," Mechanics of Composite, Hybrid and Multifunctional Materials, vol 5, pp 109-125, 2019 [14] M.Subrahmanyam and Nancharaiah, "Optimization of process parameters in wire- Material Today, vol 23, pp 642-646, 2020 [15] C Deng, Z Liu, M Zhang, Y Ji and H Pan, "Minimizing drum-shaped inaccuracy in high-speed wire electrical discharge machining after multiple cuts," Springer, no 102, p 241 251, 2019 [16] D.F.Dauw "High-Precision Wire-EDM by Online Wire Positioning Control," Elsevier, vol 43, no 1, pp 193-197, 1994 [17] N Yasir "Parametric optimization of material removal rate, surface roughness, and kerf width in high-speed wire electric discharge machining (HS-WEDM) of DC53 die steel," Springer, no 107, p 3231 3245, 2020 [18] A Q Jaber E "Principles and Characteristics of Di_erent EDM Processes in Machining Tool and Die Steels," Applied Sciences, vol 10, no 6, 2020 [19] G E.Bud The EDM handbook Cincinnati: Hanser Gardner Publications, 1997 [20] Sodick, Wire EDM Machine Operation, 1998 [21] Sodick - Product data sheet VZ300L - 1870323 57 o [22] Sodick, Envoy-edm-brass-wire-sodick-japan-dia-0-15-mm-hard,[Catalogue], Japan: Sodick [23] Mitutoyo - Product data sheet Digital Micrometer IP65 0-25, with output, item number 293-230-30 [24] Product data sheet Surftest SJ-210- 178-561-02A Surface Roughness Tester [25] http://www.jadever.vn/san-pham-jadever/canban-jwi3000w.html, 2021 [26] , - 1870323 Nxb 58 I T II A CH C o, S n tho i: 0397385619 a ch TP H III O i h c: -2018 i h c: 2021 - 1870323 59 IV -02/2020 - 1870323 - CNC 60 ... - C ng: c - t nh ng chi ti 15o 10 o M m: c t nh ng chi ti 2.2.9 diameter) - ng chi ti cao l m nc cs y ng chi u cao c a chi ti ng chi ti t cao c n l a ch - nt bo cung c a chi ti t so v - Khi... l m 3.4.1 m m t C th x a chi ti t s ab ng x ud xu chi u cao chi ti ud n yt i, ph i ch y ki ng a chi ti t ta ch ki m tra t i m t c t im im tc 3.8 l b nt ct - 1870323 a chi ti t 3.9 tb 22 3.8 3.9... of machining parameters on surface quality and costs with high-thickness of workpiece using wire-cut edm - u t ng quan v - nv tv u p ng c v nt i gian ng - Thi t k - Ti - II n c c d ng i gian