Parametric Optimization of Electric Discharge Machining for AISI 1045 Steel: A Comprehensive Study

Muhammad Mansoor Uz Zaman Siddiqui; Syed Amir Iqbal; Ali Zulqarnain; Adeel Tabassum

doi:10.36561/ING.28.15

Autores

Muhammad Mansoor Uz Zaman Siddiqui NED University of Engineering and Technology, Pakistán https://orcid.org/0009-0007-8992-7601
Syed Amir Iqbal NED University of Engineering and Technology, Pakistán https://orcid.org/0000-0002-6812-6238
Ali Zulqarnain NED University of Engineering and Technology, Pakistán https://orcid.org/0000-0003-2762-5409
Adeel Tabassum NED University of Engineering and Technology, Pakistán https://orcid.org/0009-0006-9375-1090

DOI:

https://doi.org/10.36561/ING.28.15

Palavras-chave:

Usinagem por Descarga Elétrica, AISI 1045, Otimização Paramétrica, Taxa de Remoção de Material, Taxa de Desgaste do Eletrodo, Rugosidade da Superfície, Tempo de Usinagem, Metodologia de Superfície de Resposta, ANOVA, Raio da Base

Resumo

Este estudo investiga a otimização dos parâmetros de usinagem por descarga elétrica (EDM) para AISI 1045. É um aço de médio carbono comumente usado nas indústrias automotiva e aeroespacial devido à sua resistência, tenacidade e usinabilidade equilibradas. No entanto, atingir a eficiência de usinagem ideal com excelente acabamento superficial em curto espaço de tempo e sem desperdiçar excesso de material com EDM continua sendo um grande desafio. A pesquisa se concentra na otimização dos principais parâmetros de entrada de EDM, como corrente (LV), tensão (HV), tempo de pulso ligado (Ton) e tempo de pulso desligado (Toff), para melhorar o tempo de usinagem (Tm), taxa de remoção de material (MRR), taxa de desgaste do eletrodo (EWR), rugosidade da superfície (Ra) e raio da base (R). O planejamento fatorial completo e a Metodologia de Superfície de Resposta (RSM) foram usados para conduzir experimentos e ANOVA foi empregada para identificar os fatores mais significativos que influenciam as respostas de saída. A otimização multiobjetivo foi realizada por meio da função de desejabilidade e os resultados foram validados por experimentos repetidos. Os resultados mostraram que o tempo de pulso ligado (Ton), sua interação com o tempo de pulso desligado (Toff) e a interação de três fatores entre corrente (LV), Ton e Toff foram os fatores mais significativos que afetaram o desempenho da usinagem. A otimização desses parâmetros reduziu o tempo de usinagem (Tm) para 623,21 segundos, melhorando significativamente a eficiência da EDM. A taxa de remoção de material (MRR) foi maximizada em 0,0173 g/min, resultando em um aumento considerável na eficiência da remoção de material. A taxa de desgaste do eletrodo (EWR) foi minimizada para 0,0088 g/min, o que prolonga a vida útil do eletrodo e reduz os custos operacionais. A rugosidade da superfície (Ra) foi melhorada para 0,0253 mm, garantindo um acabamento superficial de alta qualidade. O raio da base (R) foi otimizado com sucesso para 1,5298 mm, alinhando-se estreitamente com o alvo desejado de 1,5 mm, garantindo assim a precisão dimensional. Este estudo investigativo sobre a otimização de parâmetros para eletroerosão do material AISI 1045 é extremamente significativo para as indústrias automotiva e aeroespacial que dependem de usinagem de precisão, visto que os parâmetros otimizados de eletroerosão levam a uma maior eficiência, redução do desperdício de material e melhoria da qualidade do produto. Essas descobertas oferecem insights valiosos para o aprimoramento dos processos de eletroerosão, particularmente em setores que exigem geometrias complexas e alta precisão, como a indústria automotiva e aeroespacial.

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