Sustainable machining: process energy optimisation of wire electrodischarge machining of Inconel and titanium superalloys

Janaka R. Gamage, Anjali K.M. DeSilva, Dimitrios Chantzis, Mohammad Antar

Research output: Contribution to journalArticle

28 Downloads (Pure)

Abstract

Process energy optimisation is vital in view of the environmental performance of electrodischarge machining (EDM). This research is focused on identifying the significant parameters that optimise the process energy consumption of wire EDM (WEDM) of superalloys: Inconel-718 and Ti64Al4V. Four general parameters: workpiece material, workpiece thickness, wire material, and wire diameter; and four discharge parameters: gap voltage, peak current, pulse-ON time, and pulse-OFF time were tested against specific energy consumption (SEC) and surface quality of the cut. Taguchi design of experiments and analysis of variance (ANOVA) methods were used for experimentation and analysis. The Green House Gas Protocol is used to analyse potential reductions in carbon emissions. The results indicate that preferred parameters to minimise the specific energy consumption are workpiece thickness, wire material, wire diameter, and pulse-OFF time in the order of significance. It is found that 2/3rd of the total energy was consumed during non-working hours which can potentially be saved. Further, the reduction of carbon emissions corresponds to non-working energy consumption of the machines is also presented.
Original languageEnglish
Pages (from-to)642-651
Number of pages10
JournalJournal of Cleaner Production
Volume164
Early online date21 Jun 2017
DOIs
Publication statusPublished - Oct 2017

Fingerprint

Superalloys
titanium
Machining
Titanium
Wire
Energy utilization
carbon emission
Carbon
variance analysis
Analysis of variance (ANOVA)
greenhouse gas
Greenhouse gases
Design of experiments
Surface properties
energy process
parameter
energy consumption
Energy consumption
Energy
energy

Keywords

  • sustainable machining
  • wire EDM
  • process energy
  • superalloys

Cite this

@article{acd2748769a740a19d1b4895f8942e5c,
title = "Sustainable machining: process energy optimisation of wire electrodischarge machining of Inconel and titanium superalloys",
abstract = "Process energy optimisation is vital in view of the environmental performance of electrodischarge machining (EDM). This research is focused on identifying the significant parameters that optimise the process energy consumption of wire EDM (WEDM) of superalloys: Inconel-718 and Ti64Al4V. Four general parameters: workpiece material, workpiece thickness, wire material, and wire diameter; and four discharge parameters: gap voltage, peak current, pulse-ON time, and pulse-OFF time were tested against specific energy consumption (SEC) and surface quality of the cut. Taguchi design of experiments and analysis of variance (ANOVA) methods were used for experimentation and analysis. The Green House Gas Protocol is used to analyse potential reductions in carbon emissions. The results indicate that preferred parameters to minimise the specific energy consumption are workpiece thickness, wire material, wire diameter, and pulse-OFF time in the order of significance. It is found that 2/3rd of the total energy was consumed during non-working hours which can potentially be saved. Further, the reduction of carbon emissions corresponds to non-working energy consumption of the machines is also presented.",
keywords = "sustainable machining, wire EDM, process energy, superalloys",
author = "Gamage, {Janaka R.} and DeSilva, {Anjali K.M.} and Dimitrios Chantzis and Mohammad Antar",
note = "Requested AAM 10-7-17 Acceptance email in SAN AAM: 12m embargo",
year = "2017",
month = "10",
doi = "10.1016/j.jclepro.2017.06.186",
language = "English",
volume = "164",
pages = "642--651",
journal = "Journal of Cleaner Production",
issn = "0959-6526",
publisher = "Elsevier B.V.",

}

Sustainable machining: process energy optimisation of wire electrodischarge machining of Inconel and titanium superalloys. / Gamage, Janaka R.; DeSilva, Anjali K.M.; Chantzis, Dimitrios; Antar, Mohammad .

In: Journal of Cleaner Production, Vol. 164, 10.2017, p. 642-651.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Sustainable machining: process energy optimisation of wire electrodischarge machining of Inconel and titanium superalloys

AU - Gamage, Janaka R.

AU - DeSilva, Anjali K.M.

AU - Chantzis, Dimitrios

AU - Antar, Mohammad

N1 - Requested AAM 10-7-17 Acceptance email in SAN AAM: 12m embargo

PY - 2017/10

Y1 - 2017/10

N2 - Process energy optimisation is vital in view of the environmental performance of electrodischarge machining (EDM). This research is focused on identifying the significant parameters that optimise the process energy consumption of wire EDM (WEDM) of superalloys: Inconel-718 and Ti64Al4V. Four general parameters: workpiece material, workpiece thickness, wire material, and wire diameter; and four discharge parameters: gap voltage, peak current, pulse-ON time, and pulse-OFF time were tested against specific energy consumption (SEC) and surface quality of the cut. Taguchi design of experiments and analysis of variance (ANOVA) methods were used for experimentation and analysis. The Green House Gas Protocol is used to analyse potential reductions in carbon emissions. The results indicate that preferred parameters to minimise the specific energy consumption are workpiece thickness, wire material, wire diameter, and pulse-OFF time in the order of significance. It is found that 2/3rd of the total energy was consumed during non-working hours which can potentially be saved. Further, the reduction of carbon emissions corresponds to non-working energy consumption of the machines is also presented.

AB - Process energy optimisation is vital in view of the environmental performance of electrodischarge machining (EDM). This research is focused on identifying the significant parameters that optimise the process energy consumption of wire EDM (WEDM) of superalloys: Inconel-718 and Ti64Al4V. Four general parameters: workpiece material, workpiece thickness, wire material, and wire diameter; and four discharge parameters: gap voltage, peak current, pulse-ON time, and pulse-OFF time were tested against specific energy consumption (SEC) and surface quality of the cut. Taguchi design of experiments and analysis of variance (ANOVA) methods were used for experimentation and analysis. The Green House Gas Protocol is used to analyse potential reductions in carbon emissions. The results indicate that preferred parameters to minimise the specific energy consumption are workpiece thickness, wire material, wire diameter, and pulse-OFF time in the order of significance. It is found that 2/3rd of the total energy was consumed during non-working hours which can potentially be saved. Further, the reduction of carbon emissions corresponds to non-working energy consumption of the machines is also presented.

KW - sustainable machining

KW - wire EDM

KW - process energy

KW - superalloys

U2 - 10.1016/j.jclepro.2017.06.186

DO - 10.1016/j.jclepro.2017.06.186

M3 - Article

VL - 164

SP - 642

EP - 651

JO - Journal of Cleaner Production

JF - Journal of Cleaner Production

SN - 0959-6526

ER -