scholarly journals Multi-response optimization in wire electrical discharge machining (WEDM) of D2 steel using utility approach

2021 ◽  
Vol 8 ◽  
pp. 16
Author(s):  
Ipsita Nayak ◽  
Jaydev Rana
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Performance ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Response Optimization ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter ◽  
Utility Approach

Wire electrical discharge machining (WEDM) is a popular non-conventional machining process used particularly for making extrusion dies, blanking punches, and tools especially requiring tight dimensional tolerances. Because of the process limitation, the rate of cutting and maintenance of close dimensional tolerance is a challenging task. Given the above facts, the present work has been focused on achieving the maximum possible cutting rate (VC) maintaining good dimensional accuracy and corner radius (RC). In the present research work, a multi-response optimization method (i.e. Taguchi based Utility approach) has been used to obtain an optimum set of input parameters such as pulse on time (TON), pulse off time (TOFF), servo voltage (SV), and wire feed rate (WF) resulting into a best overall cutting performance. Analysis of variance (ANOVA) is also used to find out the significant effect of each machining parameter on the cutting performance. The analysis reported in this paper will be helpful for industry personnel to select the best set of process parameters for achieving a good result without the use of any software or statistical analysis.

Parameter optimization and experimental study on wire electrical discharge machining of porous Ni40Ti60 alloy

2015 ◽  
Vol 231 (6) ◽  
pp. 956-970 ◽  
Author(s):  
Neeraj Sharma ◽  
Tilak Raj ◽  
Kamal Kumar Jangra
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Influence Of Process Parameters ◽  
Work Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Response Variables

NiTi is a shape memory alloy, mostly employed in cardiovascular stents, orthopedic implants, orthodontic wires, micro-electromechanical systems and so on. The effective and net shape machining of NiTi is very critical for excellent response of this material in medical and other applications. The present experimental work on wire electrical discharge machining process identifies the influence of process parameters that affect the cutting rate, dimensional shift and surface roughness while machining of porous nickel–titanium (Ni40Ti60) alloy. Porous Ni40Ti60 alloy was produced in-house using powder metallurgy technique. Response surface methodology–based central composite rotatable design has been used for the planning of experiments on wire electrical discharge machining. Empirical relations have been developed between the process parameters (pulse on-time, pulse off-time, servo voltage and peak current) and response variables. Desirability approach has been used for optimizing the three response variables simultaneously. Confirmation experiments were also performed at the optimized settings and reflect a close agreement between the predicted and experimental values (percentage error varies from −6.13% to +6.85%). Using wire electrical discharge machining, NiTi alloy can be machined easily and successfully in single-cutting operation, but after the first cut in wire electrical discharge machining, a surface projection appears on work surface which is the unmachined material on work surface.

Multi-Objective Optimization of Wire Electrical Discharge Machining (WEDM) Process Parameters Using Weighted Sum Genetic Algorithm Approach

2016 ◽  
Vol 15 (02) ◽  
pp. 85-100 ◽  
Author(s):  
P. C. Padhi ◽  
S. S. Mahapatra ◽  
S. N. Yadav ◽  
D. K. Tripathy
Keyword(s):  
Genetic Algorithm ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Wire Electrical Discharge Machining ◽  
Weighted Sum ◽  
Multi Objective ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter ◽  
Wedm Process

The present work is aimed at optimizing the cutting rate (CR), surface roughness (Ra) and dimensional deviation (DD) in wire electrical discharge machining (WEDM) of EN-31 steel considering various input parameters such as pulse-on-time, pulse-off-time, wire tension, spark gap set voltage and servo feed. A face centered central composite design of response surface methodology (RSM) has been adopted to develop the empirical model for the responses. It is often desired to obtain a single parameter setting that can decrease Ra and DD and increase CR simultaneously. Since the responses are conflicting in nature, it is difficult to obtain a single combination of cutting parameters satisfying all the objectives in any one solution. The optimum search of the machining parameter values for maximization of CR and minimization of Ra and DD are formulated as a multi-objective, multi-variable, nonlinear optimization problem using genetic algorithm weighted sum method to evaluate the performance.

scholarly journals Parametric Optimization and Effect of Nano-Graphene Mixed Dielectric Fluid on Performance of Wire Electrical Discharge Machining Process of Ni55.8Ti Shape Memory Alloy

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2533
Author(s):  
Rakesh Chaudhari ◽  
Jay Vora ◽  
L.N.López de Lacalle ◽  
Sakshum Khanna ◽  
Vivek K. Patel ◽  
...  
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Nano Graphene ◽  
Pulse On Time ◽  
Pulse Off Time

In the current scenario of manufacturing competitiveness, it is a requirement that new technologies are implemented in order to overcome the challenges of achieving component accuracy, high quality, acceptable surface finish, an increase in the production rate, and enhanced product life with a reduced environmental impact. Along with these conventional challenges, the machining of newly developed smart materials, such as shape memory alloys, also require inputs of intelligent machining strategies. Wire electrical discharge machining (WEDM) is one of the non-traditional machining methods which is independent of the mechanical properties of the work sample and is best suited for machining nitinol shape memory alloys. Nano powder-mixed dielectric fluid for the WEDM process is one of the ways of improving the process capabilities. In the current study, Taguchi’s L16 orthogonal array was implemented to perform the experiments. Current, pulse-on time, pulse-off time, and nano-graphene powder concentration were selected as input process parameters, with material removal rate (MRR) and surface roughness (SR) as output machining characteristics for investigations. The heat transfer search (HTS) algorithm was implemented for obtaining optimal combinations of input parameters for MRR and SR. Single objective optimization showed a maximum MRR of 1.55 mm3/s, and minimum SR of 2.68 µm. The Pareto curve was generated which gives the optimal non-dominant solutions.

scholarly journals Performance evaluation of wire electrical discharge machining on Titanium Alloy

2018 ◽  
Vol 1 (1) ◽  
pp. 27-38
Author(s):  
Jun Qi Tan ◽  
Mohd Yazid Abu
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Machining Parameter

The experimental carried out to aim at the selection of the best condition machining parameter combination for wire electrical discharge machining (WEDM) of titanium alloy (Ti–6Al–4V). By using Design Expert 10 software, a series of experiments were performed by selecting pulse-on time, pulse-off time, servo voltage and peak current as parameters. The responses that considered were cutting speed, material removal rate, sparking gap and surface roughness. Based on ANOVA analysis, the effect from the parameters on the responses was determined. The optimum machining parameters setting for the maximum cutting speed, minimum sparking gap and minimum surface roughness were found by proceed optimization experiment. Then, each optimization response had their own combination setting on WEDM to cut titanium alloy. 3D response surface graph such as dome and bowl shape represent maximum and minimum point for the solutions had shown in the report. Finally, predicted and actual value from the experiment have been calculated for validation.

Enhancing die corner accuracy using path modification strategy in wire electrical discharge machining of Monel 400

2016 ◽  
Vol 232 (2) ◽  
pp. 207-216 ◽  
Author(s):  
G Selvakumar ◽  
KG Thiruppathi Kuttalingam ◽  
M Selvaraj ◽  
J Manohar
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Scanning Electron Micrographs ◽  
Controllable Factors ◽  
Monel 400 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Path Modification

In this study, path modification strategy is used to improve the accuracy of the die corner produced in wire electrical discharge machining process. Based on Taguchi’s L18 array, experiments are performed on Monel 400 alloy. The influence of the machine-controllable factors such as wire tension, open-circuit voltage, pulse-on time, pulse-off time and additional travel and uncontrollable factors namely corner angles and flushing nozzle height on the performance measures such as surface roughness, cutting speed, and corner error are studied. The outcome of this study reveals that the path modification value in terms of additional travel of 0.5 mm improves the corner accuracy of the profile by 35% as compared to the profile machined without adopting path modification strategy. The analyses of scanning electron micrographs are carried out. Finally, an optimal technological guideline is reported for ready industrial use.

scholarly journals A Fuzzy Modelling for Selection of Machining Parameters in Wire Electrical Discharge Machining of D2 Steel

2020 ◽  
Vol 8 (5) ◽  
pp. 3045-3052
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Fuzzy Model ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Selection Of

Wire Electrical Discharge Machining (WEDM) is a widely used non-traditional machining process used for machining of hard and difficult-to-machine materials. Proper selection of machining parameters in WEDM is required for better output performance, such as Material Removal Rate (MRR), Wire Wear Rate (WWR) and Surface Roughness (SR) etc. In the present paper, Pulse ON time, Pulse OFF time, Peak Current, Spark Voltage, Wire Feed and Wire Tension were taken as the input parameters to optimize MRR, WWR and SR. A set of 27 experiments were performed as per Taguchi Design. A Fuzzy model has been proposed to select the optimum values of machining parameters. The proposed fuzzy model was found to predict the experimental values with more than 90 percent accuracy.

Surface Roughness at Wire Electrical Discharge Machining

2015 ◽  
Vol 760 ◽  
pp. 551-556 ◽  
Author(s):  
Oana Dodun ◽  
Laurenţiu Slătineanu ◽  
Margareta Coteaţă ◽  
Vasile Merticaru ◽  
Gheorghe Nagîţ
Keyword(s):  
Surface Roughness ◽  
Empirical Model ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Roughness Parameter ◽  
Wire Electrical Discharge Machining ◽  
Power Type ◽  
Surface Roughness Parameter ◽  
Pulse On Time ◽  
Pulse Off Time

Wire electrical discharge machining is a machining method by which parts having various contours could be detached from plate workpieces. The method uses the electrical discharges developed between the workpiece and the wire tool electrode found in an axial motion, when in the work zone a dielectric fluid is recirculated. In order to highlight the influence exerted by some input process factors on the surface roughness parameter Ra in case of a workpiece made of an alloyed steel, a factorial experiment with six independent variables at two variation levels was designed and materialized. As input factors, one used the workpiece thickness, pulse on time, pulse off-time, wire axial tensile force, current intensity average amplitude defined by setting button position and travelling wire electrode speed. By mathematical processing of the experimental results, empirical models were established. Om the base of a power type empirical model, graphical representations aiming to highlight the influence of some input factors on the surface roughness parameter Ra were achieved. The power type empirical model facilitated establishing of order of factors able to exert influence on the surface roughness parameter Ra at wire electrical discharge machining.

scholarly journals Multi-Objective Optimization of Wire Electrical Discharge Machining of AL 2124/SIC Composite

2019 ◽  
Vol 9 (1) ◽  
pp. 2155-2163
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Strength ◽  
Wire Electrical Discharge Machining ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Predicted Values ◽  
Pulse On Time ◽  
Pulse Off Time

The growing demand for the use of high strength to weight alloys in industries for manufacturing complex structures challenges the machinability of such advanced materials. In the present investigation, the machinability of SiC particle reinforced Al 2124 composite was studied on Wire electrical discharge machining (WEDM). The process parameters namely pulse on-time (Ton), pulse off time (Toff), peak current (IP), and servo voltage (SV) were optimized by utilizing the central composite design layout. The output responses such as kerf and material removal rate (MRR) were studied in detail. The single and multi-objective optimization was studied for a combination effect using Derringer’s desirability approach and Genetic Algorithm (GA). The experimental and predicted values for each response were validated at the optimized condition. The experimental results were found in line with the predicted values. Multi objective optimization of kerf and MRR by GA showing better result compared to RSM.

Multi Response Optimization of Electrical Discharge Machining Process Parameters Using Sintered Copper Electrode

2012 ◽  
Vol 622-623 ◽  
pp. 19-24
Author(s):  
P. Balasubramanian ◽  
Thiyagarajan Senthilvelan
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Machining Process ◽  
Sintered Copper ◽  
Response Optimization ◽  
Electric Pressure ◽  
Pulse On Time

In this study, input parameters of Electrical Discharge machining (EDM) process have been optimised for two different materials EN-8 and Die steel-D3 were machined by using sintered copper electrode. Analysis of variance (ANOVA) was applied to study the influences of process parameters viz: - peak current, pulse on time, di-electric pressure and diameter of electrode on material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) for both materials. Response surface methodology (RSM) has been applied to optimise the multi responses in order to get maximum MRR, minimum TWR and minimum SR. Furthermore, mathematical model has been formulated to estimate the corresponding output responses for both work pieces. It has been observed that compared to EN 8 material, the MRR value is low and TWR is high for D3 material. However the SR value is marginally lower than obtained in EN8.R2 value is above 0.90 for both work pieces.

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