scholarly journals Modeling and experimental investigation of process parameters in WEDM for surface roughness using regression model

2018 ◽  
Vol 172 ◽  
pp. 04010
Author(s):  
A. Muniappan ◽  
R. Senthilkumar ◽  
V. Jayakumar ◽  
S. Venkata Ravikumar ◽  
P. Sai Tarunkumar
Keyword(s):  
Surface Roughness ◽  
Multiple Regression ◽  
Process Parameters ◽  
Wire Tension ◽  
Level 3 ◽  
Level 1 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time

The present study focused on the multiple regression modeling and predicting the surface roughness of the Aluminum hybrid composite during the WEDM process. The hybrid MMC was manufactured by process named as stir casting utilizing particulates of Silicon carbide and graphite each in Al6061 combination. The analyses were outlined with Taguchi L27 design matrix. Mathematical relationships between the surface roughness and WEDM cutting parameters (Pulse on time, Pulse off time, current, gap voltage, wire speed and wire tension) have been investigated. The results show that the multiple regression analysis is a successful method for developing a mathematical model to predict the surface roughness. The optimum value of process parameters for the predicted optimum value of surface roughness (1.285) is pulse on time 106 units (Level 1), pulse off time 60 units (Level 3), peak current 90 units (Level 2), gap set voltage 50 units (Level 3), wire speed3 units (Level 1) and wire tension 12 units (Level 3).The optimum results are adopted in validation study and the results based on WEDM process responses can be effectively improved.

scholarly journals Multi-Objective Optimization of Wire Electro Discharge Machining (WEDM) Process Parameters Using Grey-Fuzzy Approach

2018 ◽  
Vol 63 (1) ◽  
pp. 16-25 ◽  
Author(s):  
Partha Protim Das ◽  
Sunny Diyaley ◽  
Shankar Chakraborty ◽  
Ranjan Kumar Ghadai
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Machining Process ◽  
Wire Tension ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Fuzzy Logic Technique ◽  
Off Time

Wire electro discharge machining (WEDM) is a versatile non-traditional machining process that is extensively in use to machine the components having intricate profiles and shapes. In WEDM, it is very important to select the optimal process parameters so as to enhance the machine performance. This paper emphasizes the selection of optimal parametric combination of WEDM process while machining on EN31 steel, using grey-fuzzy logic technique. Process parameters such as servo voltage, wire tension, pulse-on-time and pulse-off-time were considered while taking into account several multi-responses such as material removal rate (MRR) and surface roughness (SR). It was found that pulse-on-time of 115 µs, pulse-off-time of 35 µs, servo voltage of 40 V and wire tension of 5 kgf results in a larger value of grey fuzzy reasoning grade (GFRG) which tends to maximize MRR and improve SR. Finally, analysis of variance (ANOVA) is applied to check the influence of each process parameters in the estimation of GFRG.

Surface Roughness Optimization of Wire Electrical Discharge Machining Using ABC Algorithm

2015 ◽  
Vol 766-767 ◽  
pp. 902-907
Author(s):  
Bibin K. Tharian ◽  
B. Kuriachen ◽  
Josephkunju Paul ◽  
Paul V. Elson
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Wire Tension ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm2, servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

scholarly journals Utility approach for multi target streamlining of process parameters in wire EDM

2018 ◽  
Vol 172 ◽  
pp. 04006
Author(s):  
A. Muniappan ◽  
M. Ajithkumar ◽  
V. Jayakumar ◽  
C. Thiagarajan ◽  
M. Sreenivasulu
Keyword(s):  
Machining Parameters ◽  
Wire Edm ◽  
Time Duration ◽  
Level 3 ◽  
Level 1 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Utility Approach ◽  
Wire Feed

This paper depicts the improvement of multireaction enhancement system utilizing utility technique to foresee and select the ideal setting of machining parameters in wire electro-release machining (WEDM) process. Investigations were arranged utilizing Taguchi's L27 orthogonal exhibit. A wide range of Wire EDM control variables such as pulse on time duration, pulse off time duration, servo voltage along with wire feed rate were judged for investigation. Multi reaction enhancement was performed for both cutting pace (CS) and surface unpleasantness (SR) utilizing utility idea to discover the ideal procedure parameter setting. The level of essentialness of the machining parameters for their impact on the CS and SR were controlled by utilizing investigation of fluctuation (ANOVA). In present study utility approach method used to optimize the process parameter in wire EDM of magnesium Al6061/SiC/Graphite hybrid composite with zinc covered brass wire electrode. The approach depicted here is relied upon to be profoundly useful to assembling enterprises, and furthermore different territories, for example, aviation, car and apparatus making businesses. The parameters corresponding to experiment run number 7 are pulse on time 108 units (Level 1), pulse off time 60 units (Level 3), peak current 230 units (Level 3), gap set voltage 60 units (Level 3), wire feed 3 units (Level 1) and wire tension 4 units (Level 1) are the best combination to achieve better surface roughness and cutting speed.

Surface Study in a Non-conventional (Electrical Discharge Machining) Process for Grade 6 Titanium Material

2014 ◽  
Vol 68 (1) ◽  
Author(s):  
Md. Ashikur Rahman Khan ◽  
M. M. Rahman
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Machined Surface ◽  
Titanium Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Electrical discharge machining (EDM) produces complex shapes and permits high-precision machining of any hard or difficult-to-cut materials. The performance characteristics such as surface roughness and microstructure of the machined face are influenced by numerous parameters. The selection of parameters becomes complicated. Thus, the surface roughness (Ra) and microstructure of the machined surface in EDM on Grade 6 titanium alloy are studied is this study. The experimental work is performed using copper as electrode material. The polarity of the electrode is maintained as negative. The process parameters taken into account in this study are peak current (Ip), pulse-on time (Ton), pulse-off time (Toff), and servo-voltage (Sv). A smooth surface finish is found at low pulse current, small on-time and high off-time. The servo-voltage affects the roughness diversely however, a finish surface is found at 80 V Sv. Craters, cracks and globules of debris are appeared in the microstructure of the machined part. The size and degree of craters as well as cracks increase with increasing in energy level. Low discharge energy yields an even surface. This approach helps in selecting proper process parameters resulting in economic EDM machining. 

Optimization of WEDM process parameters in machining Nimonic 75 alloy using brass wire

2020 ◽  
Vol 16 (5) ◽  
pp. 1189-1202 ◽  
Author(s):  
Harvinder Singh ◽  
Vinod Kumar ◽  
Jathinder Kapoor
Keyword(s):  
Removal Efficiency ◽  
Process Parameters ◽  
Material Removal ◽  
Kerf Width ◽  
Content Type ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Nimonic 75 ◽  
Off Time

PurposeAn experimental study has been conducted to model and optimize wire electric discharge machining (WEDM) process parameters such as pulse-on time, pulse-off time, servo voltage and peak current for response characteristics during machining of Nimonic 75 alloy.Design/methodology/approachThe response surface methodology (RSM)-based Box–Behnken's design has been employed for experimental investigation. RSM is used for developing quadratic regression models for selected response variables i.e. material removal efficiency and kerf width. To validate the model, confirmation experiments have been performed. The multi-response optimization has been done using desirability function approach.FindingsThrough analysis of variation, the percent contribution of process parameters on the response characteristics has been found. Pulse-off time is the most significant parameter affecting the kerf width and material removal efficiency followed by pulse-on time. The quadratic regression models have been developed for prediction of selected response variables. An attempt has been made to optimize the WEDM parameters for material removal efficiency and kerf width. The recommended process parameter setting for maximum material removal efficiency and minimum kerf width have been found to be pulse-on time = 0.6 µs, pulse-off time = 14 µs, servo voltage = 25 V and peak current = 200 A.Originality/valueThe “kerf width” is an important response variable for maintaining dimensional accuracy of the machined component, but has not been given due attention by the researchers. In the present work, the developed regression model for “kerf width” can be used in estimating wire offset setting and thereby getting a dimensionally accurate product. The optimum process parameters obtained in WEDM of Nimonic 75 alloy will contribute in database of machining. The outcome of this study would be added to scare database of the machining of Nimonic 75 alloy and also would be extremely useful for making the technology charts for WEDM.

Experimental Investigation of Process Parameters in Wire Electrical Discharge Machining by Response Surface Methodology on IS2062 Steel

2014 ◽  
Vol 550 ◽  
pp. 53-61
Author(s):  
R.Arun Bharathi ◽  
P.Ashoka Varthanan ◽  
K. Manoj Mathew
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Machining Parameters ◽  
Peak Current ◽  
Custom Design ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The objective of the present work is to predict the optimal set of process parameters such as peak current (IP), pulse on/off time (TON/TOFF) and spark gap voltage (SV) to achieve minimum Surface roughness (Ra), wire consumption rate (WCR) and maximum material removal rate (MRR). In this work, experiments were carried out by pulse arc discharges generated between ZnO coated brass wire and specimen (IS2062 steel) suspended in deionized water dielectric. The experiments were designed based on the above mentioned four factors, each having three levels. Custom design based Response Surface Methodology (RSM) is used in this research. 21 runs of experiments were constructed based on custom design procedure and results of the experimentation were analyzed analytically as well as graphically. Moreover the surface roughness after machining was measured by Taylor Hobson Surtronic device. Second order regression model has been developed for predicting Ra, WCR and MRR in terms of interactive and higher order machining parameters through RSM, utilizing relevant experimental data as obtained through experimentation. The research outcome identifies significant parametersand their effect on process performance on IS2062 steel. The results revealed that peak current, pulse on-time and their interactions have significant effects on Ra, whereas pulse off time and peak current have significant effects on MRR and it is also observed that peak current and interaction between peak current and pulse off time have significant effects on WCR. The adequacy of the above proposed models has been tested through the analysis of variance (ANOVA).

scholarly journals Analysis of WEDM Process Parameters on Surface Roughness and Kerf using Taguchi Method

2017 ◽  
Vol 2 (4) ◽  
pp. 103-109 ◽  
Author(s):  
Asfana Banu ◽  
Mazilah Abu Bakar ◽  
Mohammad Yeakub Ali ◽  
Erry Y. T. Adesta
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Machining Parameters ◽  
Wire Tension ◽  
Wedm Process ◽  
Off Time

In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap. 

scholarly journals Taguchi Optimization In Machining Inconel 600 With WEDM Process Using Cryogenically Treated Brass Wire

2021 ◽  
Vol 309 ◽  
pp. 01110
Author(s):  
K. Satyanarayana ◽  
B Ramya Krishna ◽  
M. Bhargavi ◽  
R. Eswari Vasuki ◽  
K. Raj Kiran
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Inconel 600 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time ◽  
Brass Wire

Wire electric discharge machining (WEDM) is one amongst the unconventional machining processes which might cut all kinds of shapes with an accuracy of +/−0.001mm. It will cut the materials that conduct electricity and can even cut the exotic metals like tungsten carbide, Hastelloy, Inconel etc. In the present work, machining on Inconel 600 by wire EDM with cryogenically treated brass wire is performed. Brass wire of 0.25mm diameter has been cryogenically treated at −90°C, −100°C and −110°C temperatures separately. An Experimental layout is designed as per Taguchi’s L-9 orthogonal array and experiments were conducted by varying machining parameters viz. Voltage, Pulse ON time and Pulse OFF time. The machining parameters are optimized using Taguchi’s methodology for minimum surface roughness and maximum metal removal rate (MRR). A Mathematical regression model for surface roughness and MRR is generated with the help of regression analysis. Through the Analysis of Variance (ANOVA) It was found that for MRR, pulse on time is the foremost contributing factor with 32.69% and for surface roughness, pulse off time is the foremost contributing factor with 23.59%.

Optimization of WEDM Process Parameters for MRR and Surface Roughness using Taguchi-Based Grey Relational Analysis

2015 ◽  
Vol 2 (1) ◽  
pp. 1-25 ◽  
Author(s):  
Milan Kumar Das ◽  
Kaushik Kumar ◽  
Tapan Kumar Barman ◽  
Prasanta Sahoo
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Grey Relational Analysis ◽  
Confirmatory Test ◽  
Relational Analysis ◽  
Minimum Surface ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

This article presents an experimental study of material removal rate (MRR) and surface roughness characteristics of wire electrical discharge machining (WEDM) and the optimization of process parameters based on Taguchi method coupled with grey relational analysis for minimum surface roughness and maximum MRR. Experiments are carried out by utilizing the combination of process parameters viz. discharge current, voltage, pulse on time and pulse off time based on L27 Taguchi orthogonal array (OA). Analysis of variance (ANOVA) carried out and it reveals that current has the maximum contribution in controlling MRR and surface characteristics of WEDM. The interaction between voltage and pulse on time is also found to have significant contribution in MRR and surface roughness characteristics. The optimum combination of process parameters for maximum MRR and minimum surface roughness is obtained and the optimal setting has been verified through confirmatory test. The result shows good agreement between the predicted and experimental results. This indicates the utility of the grey-Taguchi technique as multi-objective optimizer in the field of WEDM. Also, variation of responses with process parameters are also studied using 3D surface plots. Finally, the microstructure analysis in the region of cutting surface is performed using scanning electron microscopy (SEM).

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