Dimensional accuracy and surface quality in Wire-Cut EDM of Ti6Al4V: experimental study and optimization Jaya Kishore Sunkara, P. Kumar Babu, Parveen Kumar, Ajay Kumar Journal of Engineering and Applied Science, 2025 Ti6Al4V is widely recognized for its exceptional strength-to-weight ratio and is extensively used in aerospace and biomedical applications. This study focuses on optimizing the Wire-Cut Electrical Discharge Machining (WEDM) parameters to minimize geometrical and dimensional errors, such as cylindricity, perpendicularity, dimensional deviation (DD), and taper. The main objective is to enhance machining precision, improve surface integrity, and extend the performance and lifespan of the assembled components. The experimental design was developed using the Taguchi L9 Orthogonal Array (OA) for three key process parameters Pulse-on Time (T ON ), Pulse off Time (T OFF ), and Control of Servo (CS) each at three levels. This approach effectively reduced the number of required experiments while maintaining a robust analysis. The Gray Relational Analysis (GRA) technique was subsequently applied to obtain a global optimum for multiple response optimization. Regression equations were developed to establish relationships between the process parameters and responses, and validation was performed at a 95% confidence level. The experimental results revealed that the optimal parameter combination for the square geometry was a T ON of 110 µs, T OFF of 60 µs, and CS of 70%, whereas for the circular geometry, the best results were obtained at a T ON of 106 µs, T OFF of 58 µs, and CS of 80%. Scanning Electron Microscopy (SEM) and Optical Microscopy (OM) confirmed surface roughness values of 4.47 μm and 4.11 μm for the square and circular holes, respectively. The findings demonstrate that the optimized WEDM parameters significantly improved the machining quality, reduced the inspection time, and minimized the production costs while achieving high dimensional accuracy and superior surface finish.
Experimental control of kerf width taper during Abrasive water jet machining Sunkara Kishore, P. Teja, B. Eshwariaha, K. Reddy Fme Transactions, 2019 Abrasive water jet machining (AWJM) is one of the effective nonconventional machining processes. AWJM has its effective influence on aeronautical and automobile engineering industries. This paper aims to study the outcome of AWJM process parameters on kerf width and kerf taperness of Inconel-825. Taguchi’s DOE is designed for experimental approach. Orthogonal array L25 is selected for experimental work. The influence of various process factors such as Transverse speed, Abrasive flow rate and stand-off distance on the kerf width and kerf taperness was studied. The consequence of the machining parameters was analysed and the optimum process parameters were identified with the help of Grey’s relational analysis. Confirmation test was carried out with the optimum values of machining parameters such as Transverse speed-60mm/min, Abrasive Flow Rate-200gm/min and Stand off Distance-4mm in order to illustrate the effectiveness of Grey’s relational analysis. The Optical microscopy confirmation test is performed for characterization of morphology and identification of micro cracks.
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MOST CITED SCHOLAR PUBLICATIONS
Development and wear behavior investigation on aluminum-7075/B4C/fly ash metal matrix composites TP Reddy, SJ Kishore, PC Theja, PP Rao Advanced Composites and Hybrid Materials 3 (2), 255-265 , 2020 2020 Citations: 68
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Experimental investigation on precision machining of multiple holes by WEDM on Aluminium-6061 using genetic algorithm KBP Jaya Kishore Sunkara , Siva Kumar Kayam, Gopala Krishna Monduru Multiscale and Multidisciplinary Modeling, Experiments and Design 2 (4), 1-12 , 2019 2019 Citations: 11
Design and Analysis of Composite Marine Propeller using ANSYS WORKBENCH SS S.Abdul Mutlib, S.Jaya Kishore International journal of science, Engineering and Technology Research 4 (9 … , 2015 2015 Citations: 9
Structural Analysis of Multi-Plate clutch SJ Kishore, ML Kumar International Journal of Computer Trends and Technology (IJCTT)–volume 4 , 2013 2013 Citations: 9
Experimental Parametric Studies on Hast Alloy Using Abrasive Water Jet Machining SJ Kishore, KS Kumar, MN Rao 2017 Citations: 6
Computational Geometric Modeling and Finite Element Structural Analysis of Automobile Camshaft U Mahesh, B Reddy, J Kishore Internationsl Journal of Emerging Technology and Advanced Engineering 5 (7 … , 2015 2015 Citations: 6
Development of BLDC motor controller using sensor-based method CP Reddy, M Jayakumar, K Raj, SS Pandey 2024 Second International Conference on Emerging Trends in Information … , 2024 2024 Citations: 5
Experimental Investigation of Abrasive water jet machining processes parameters & Its effects on Processes responses using Grey taguchi optimization Technique JS Sruthi,B.,Kilari,N.,Kishore Journal of Production Engineering 19 (2), 13-19 , 2016 2016 Citations: 5
FEM Analysis on Submarine Propeller Blade for Improved Efficiency by using Solid Works and ANSYS-Workbench JKS P. Kumar Babu, B. Siddeswara Rao International Journal of Emerging Engineering Research and Technology 3 (11 … , 2015 2015 Citations: 5
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FEM Analysis of Disc Brake with varying parameters & Materials for Improved efficiency using CATIA V5R20 and HYPERMESH 11 G Ashokkumar, S Jaya Kishore, PK Babu International Journal of Mechanical Engineering and Computer 2 , 2014 2014 Citations: 2
Experimental investigation of the metallurgical and mechanical properties of laser weld Inconel 825 joints for petrochemical plants M Biradar Nondestructive Testing and Evaluation 41 (1), 253-277 , 2026 2026 Citations: 1
Dimensional accuracy and surface quality in Wire-Cut EDM of Ti6Al4V: experimental study and optimization JK Sunkara, PK Babu, P Kumar, A Kumar Journal of Engineering and Applied Science 72 (1), 217 , 2025 2025 Citations: 1
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Optimisation of laser welding parameters to maximise the joint strength of laser weld stainless steel joints using a GA for geothermal plants MB Jaya Kishore S Australian Journal of Mechanical Engineering 21 (05), 01-16 , 2023 2023
Experimental Investigation of the Metallurgical and Mechanical Properties of a Nd: YAG Laser-Welded Inconel-825 Superalloy SJ Kishore, M Biradar International Conference on Processing and Fabrication of Advanced Materials … , 2023 2023
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