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. 2022 Sep 1;13(9):1446.
doi: 10.3390/mi13091446.

Efficiency Optimization of the Electroerosive Process in µ-WEDM of Steel MS1 Sintered Using DMLS Technology

Ľuboslav Straka  1 , Miroslav Gombár  2 , Alena Vagaská  3 , Patrik Kuchta  1
Affiliations

Efficiency Optimization of the Electroerosive Process in µ-WEDM of Steel MS1 Sintered Using DMLS Technology

Ľuboslav Straka et al. Micromachines (Basel). .

Abstract

Although the application of mathematical optimization methods for controlling machining processes has been the subject of much research, the situation is different for µ-WEDM. This fact has prompted us to fill the gap in this field in conjunction with investigating µ-WEDM's very low productivity and overall process efficiency, since the current trend is oriented towards achieving high quality of the machined area at a high manufacturing productivity. This paper discusses in detail the application of non-linear programming (NLP) methods using MATLAB to maximize the process performance of µ-WEDM maraging steel MS1 sintered using direct metal laser sintering (DMLS) technology. The novelty of the solution lies mainly in the selection of efficient approaches to determine the optimization maximum on the basis of a solution strategy based on multi-factor analysis. The main contribution of this paper is the obtained mathematical-statistical computational (MSC) model for predicting high productivity and quality of the machined area with respect to the the optimal efficiency of the electrical discharge process in the µ-WEDM of maraging steel MS1 material. During the experimental research and subsequent statistical processing of the measured data, a local maximum of 0.159 mm3·min-1 for the MRR parameter and a local minimum of 1.051 µm for the Rz parameter were identified simultaneously during µ-WEDM maraging steel MS1, which was in the range of the predicted optimal settings of the main technological parameters (MTP).

Keywords: efficiency; micromachining; optimization; performance; quality; surface roughness.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Experimental sample of maraging steel MS1 after DMLS.
Figure 2
Figure 2
Made of experimental samples from maraging steel MS1 by µ-WEDM. (a) µ-WEDM process of the specimens; (b) marking of roughing sections E1 to E8, (c) the used electroerosive machine CHMER G32F.
Figure 3
Figure 3
Dependence of the output power parameter of the MRR process on the change in the value of the maximum peak current I parameter at different values of ton, toff, and U. (a) Impact on MRR at minimum values of the parameter toff and U. (b) Impact on MRR at maximum values of toff and U.
Figure 4
Figure 4
Dependence of the output qualitative parameter of the Rz process on the change in the value MTP of the maximum peak current I parameter at different values of ton, toff, and U. (a) Impact on Rz at minimum values of the parameter toff and U. (b) Impact on Rz at maximum values of toff and U.
Figure 5
Figure 5
Graphical analysis of the predictive MSC models. (a) MSC model deviations for MRR. (b) MSC model deviations for Rz.
Figure 5
Figure 5
Graphical analysis of the predictive MSC models. (a) MSC model deviations for MRR. (b) MSC model deviations for Rz.
Figure 6
Figure 6
Graphical representation of the outputs of the performed optimization of the performance parameter of the µ-WEDM for maraging steel MS1.
Figure 7
Figure 7
Graphical representation of the outputs of the performed optimization of the quality parameter of the machined surface after µ-WEDM of maraging steel MS1.
See this image and copyright information in PMC

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