Comparative Study on EDM Wire Cutting and CO 2 Laser Cutting for High‐Precision Stainless Steel Sheet Processing

Comparative Study on EDM Wire Cutting and CO 2 Laser Cutting for High‐Precision Stainless Steel Sheet Processing A. Parthiban Department of Mechanical Engineering Vels Institute of Science, Technology & Advanced Studies Chennai Tamil Nadu India https://orcid.org/0000-0002-9560-0265 K. Ananthakumar ‐Metallurgist Process Engineering Department Motherson Health and Medical Systems Kanchipuram Tamil Nadu India S. Ajith Arul Daniel Department of Mechanical Engineering Vels Institute of Science, Technology & Advanced Studies Chennai Tamil Nadu India S. Sivaganesan Department of Mechanical Engineering Vels Institute of Science, Technology & Advanced Studies Chennai Tamil Nadu India T. Sathish Department of Mechanical Engineering Saveetha School of Engineering, SIMATS Chennai Tamil Nadu India https://orcid.org/0000-0003-4912-5579 Jayant Giri Department of Mechanical Engineering Yeshwantrao Chavan College of Engineering Nagpur India Division of Research and Development Lovely Professional University Phagwara India A. Johnson Santhosh Associate Professor, Faculty of Mechanical Engineering, Jimma Institute of Technology Jimma University Jimma Ethiopia https://orcid.org/0000-0003-4478-2131 Ahmad O. Hourani Hourani Center for Applied Scientific Research Al‐Ahliyya Amman University Amman Jordan ABSTRACT

CO 2 laser cutting and electrical discharge machining (EDM) wire cutting are two advanced thermal energy‐based methods widely utilized for precision profile cutting tasks. This study conducts a comprehensive experimental analysis of these techniques, focusing on their performance when cutting stainless steel grades AISI 316L and 304. The research evaluates key process parameters influencing the cut quality, aiming to achieve minimal surface roughness. Additionally, the surface morphologies resulting from both methods are thoroughly examined. By analyzing the cutting performance and tracking the outcomes for both techniques, the study identifies the most efficient cutting technology for these materials. Using a multi‐objective optimization approach based on Genetic Algorithms, the study demonstrates a significant enhancement in surface roughness. The percentages of deviations for AISI 316 Stainless steel for 1.5, 2, and 2.5 mm thickness for CO 2 laser cut and EDM wire cut surfaces are 24.8%, 21.59%, and 35.61%, respectively, and also that The percentages of deviations for AISI 304 Stainless steel for 1.5, 2, and 2.5 mm thickness for CO 2 laser cut and EDM wire cut surfaces are 36.86%, 27.88%, and 22.96%, respectively. The optimized process achieves a superior surface roughness of cutting quality. These findings offer valuable insights into selecting the appropriate cutting method and parameters for achieving high‐precision results in industrial applications.
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