HYBRID MODELING OF PROCESS PARAMETERS PRODUCED BY ELECTRIC DISCHARGE MACHINING USING DIFFERENTIAL EVALUATION AND PARTICLE SWARM OPTIMIZATION

2013 ◽  
Vol 12 (02) ◽  
pp. 147-169
Author(s):  
R. RAJESH ◽  
M. DEV ANAND
Keyword(s):  
Heat Resistance ◽  
Discharge Voltage ◽  
Machining Parameters ◽  
Peak Current ◽  
Spark Gap ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Time Pulse

One of the important advanced manufacturing technologies in machining hard-to-cut complicated contour is electrical discharge machining (EDM) and it is highly appreciated because it is economical and effective for moulding materials of heat resistance and high strength into complex one. The EDM process deals with erosion of electrically conductive materials by the way of initiating rapid and repetitive spark discharge between the work piece and electrode tool, with the separation of gap of 0.05 to 0.5 mm which is called spark gap. A die electric fluid soakes this spark gap. In EDM process machining parameters are considered to be important to achieve optimal machining performance in high heat resistance and hard material. The hand book provides all the details about the opted machining parameters but it does not guarantee that the obtained parameters are close to optimal performance. The EDM process should have the features of robustness, accuracy, process capability to confront with the challenges of the changing world. The EDM process should be modeled and optimized to achieve perfection as mentioned above. The researcher uses RSM to investigate the effect of five controllable input variables (viz) peak current, discharge voltage, pulse on time, pulse off time, and oil pressure. MRR and SR, two output variables are the responses. Experiments were administered on AISI 1020 steel with copper electrode. The response is modeled using RSM on experimental data. The remarkable coefficients are received by performing analysis of variance (ANOVA) at the level of 5%. This study shows the MRR and SR have been significantly influenced by peak current, pulse on time, pulse off time, discharge voltage and oil pressure. The soft computing tools differential evolution and PSO are framed, developed, experimented as predictive models.

scholarly journals Findings of performance evaluation of EDM for different materials of electrodes and work pieces- a review

2018 ◽  
Vol 7 (4.5) ◽  
pp. 542
Author(s):  
Harshalkumar R. Mundane ◽  
Dr. A. V. Kale ◽  
Dr. J. P. Giri
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Performance Measure ◽  
Machining Process ◽  
Machining Parameters ◽  
Spark Erosion ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

EDM (Spark erosion) is non-conventional machining process which uses as removing unwanted material by electrical spark erosion. EDM Machining parameters affecting to the performance and the industries goal is to produce high quality of product with less time consuming and cost. To achieve these goals, optimizing the machining parameters such as pulse on time, pulse off time, cutting speed, depth of cut, duty cycle, arc gap, voltage etc. The performance measure of EDM is calculated on the basis of Material Remove Rate(MRR), Tool Wear Rate(TWR), and Surface Roughness(SR).The main objective of present work is to investigate of the influence of input EDM (Electro Discharge Machining) parameters on machining characteristics like surface roughness and the effects of various EDM process parameters such as pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, on different process response parameters such as material removal rate (MRR), surface roughness (Ra), Kerf (width of Cut), tool wear ratio(TWR)and surface integrity factors. In this paper few selected research paper related to Die-sinker EDM with effect of MRR, TWR, surface roughness (SR) and work piece material have been discussed.   

A Comparison of the Effects of Wire Electrical Discharge Machining Parameters on the Processing of Traditionally Manufactured and Additively Manufactured 316L Stainless Steel Specimens

2018 ◽  
Author(s):  
Gregory Bicknell ◽  
Guha Manogharan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
316L Stainless Steel ◽  
Machining Parameters ◽  
Wire Edm ◽  
Machining Time ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire electric discharge machining (EDM) is a non-traditional machining method that has the ability to machine hard, conductive materials, with no force and high precision. This technology is used in industries, like the aerospace industry, to create precision parts used in high stress applications. Wire EDM is also commonly used in additive manufacturing (AM) applications to remove printed parts from the base-plates onto which they are printed. Numerous studies show the effects of EDM parameters, like pulse-on time, pulse-off time, and cutting voltage, on the processing of traditionally fabricated metal parts. However, very few studies identify how the parameters of wire EDM affect the processing of AM parts. This paper studies the effect of wire EDM pulse-on time, pulse-off time, and cutting voltage on the machining time, surface roughness, and hardness of additively manufactured 316L stainless steel cylinders. The effects of these wire EDM parameters are then tested on the machining time, surface roughness, and hardness of wrought 316L stainless steel cylinders. It was found that machining time of AM samples was statistically significantly lower than wrought samples and also had better surface finish and lower surface hardness.

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).

The Performance of Brass Electrode on Material Removal for Aluminium Composite in EDM Die-Sinking

2014 ◽  
Vol 660 ◽  
pp. 43-47
Author(s):  
Amran Ali Mohd ◽  
Suraya Laily ◽  
Aisyah Fatin ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Aluminium Alloys ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the performance of brass electrode on the removal of aluminium alloys LM6 (Al-Sil2) in an electrical discharge machining (EDM) die-sinking. The machining parameters such as pulse-on time, pulse-off time and peak current were selected to find the responses on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Brass with diameter of 10mm was chosen as an electrode. Orthogonal array of Taguchi method was used to develop experimental matrix and to optimize the MRR, EWR and Ra. It is found that the current is the most significantly affected the MRR, EWR and Ra while pulse on time, pulse off time and voltage are less significant factor that affected the responses. Percentage optimum value of MRR increases to 3.99%, however EWR and Ra reduce to 3.10% and 2.48% respectively. Thus, it shows that brass having capability to cut aluminium alloys LM6.

Investigation of the Effect of Process Parameters on Surface Roughness in Wire EDM of Titanium Alloy

2012 ◽  
Vol 472-475 ◽  
pp. 78-81 ◽  
Author(s):  
Mohinder Pal Garg ◽  
Ajai Jain ◽  
Gian Bhushan
Keyword(s):  
Surface Roughness ◽  
Water Pressure ◽  
Peak Voltage ◽  
Peak Current ◽  
Wire Breakage ◽  
Pulse Peak ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the Wire Electric Discharge Machining of Titanium alloy 6-2-4-2.Eight process parameters namely pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed, wire tension, water pressure, pulse peak voltage and servo feed are varied to study their effect on surface roughness and wire breakage. The experiments are conducted using one-factor-at-a-time approach. Moreover, a few random experiments are also carried to study the phenomenon of wire breakage precisely. The study revealed that surface roughness is directly affected by the pulse-on time, pulse-off time, peak- current, spark gap set voltage and wire tension. Wire feed, Water pressure and pulse peak voltage have negligible effect on the surface roughness. Moreover, wire breakage is predominantly dictated by all the parameters except peak current and pulse peak voltage. An optimum range of input parameters has been bracketed as the final outcome for cutting in terms of surface roughness and to minimize the wire breakage frequency.

scholarly journals EXPERIMENTAL INVESTIGATION OF OPTIMAL ED MACHINING PARAMETERS FOR Ti-6Al-4V BIOMATERIAL

2018 ◽  
Vol 16 (3) ◽  
pp. 337 ◽  
Author(s):  
Amandeep Singh Bhui ◽  
Gurpreet Singh ◽  
Sarabjeet Singh Sidhu ◽  
Preetkanwal Singh Bains
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Clinical Success ◽  
Machining Parameters ◽  
Machining Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

The present study investigates optimal parameters for machining of Ti-6Al-4V using EDM with graphite electrode. Herein, another technique of modifying surface properties and enhancing machining rate using electrical discharge machining (EDM) was developed. In the present study, design of experiment (D.O.E) was developed using the Taguchi’s orthogonal array to examine the effect of the input machining factors on the machining characteristics, and to forecast the optimized EDM parameters in terms of peak current, pulse-on time, pulse-off time and applied gap voltage. Each experiment was performed to obtain a hole of 1mm depth on the workpiece. From the results, it is found that the discharge current has significant influence on material removal rate (MRR) and surface roughness (SR) followed by other selected parameters, i.e. pulse-on time, pulse-off time. The MRR augmented steeply with the current and was recorded as maximum at 4 Amps. In-vitro bioactivity test was conducted in the simulated body fluid to examine bioactivity confirming a significant apatite growth on the surface treated with ED sparks. The surface and chemical alteration were analyzed by using Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD) along with the identification of the substantially enhanced morphology for clinical success.

Identification of Optimal Process Parameters in Electro-Discharge Machining Using ANN and PSO

2018 ◽  
pp. 72-90 ◽  
Author(s):  
Kaushik Kumar ◽  
J. Paulo Davim
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Repair Work ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Time Pulse

Electrical Discharge Machining (EDM) process is a widely used machining process in several fabrication, construction and repair work applications. Considering Pulse-On Time, Pulse OFF time, Peak-Current and Gap voltage as the inputs and among all possible outputs, in the present work Material Removal Rate and Surface Roughness are considered as outputs. In order to reduce the number of experiments Design of Experiments (DOE) was undertaken using Orthogonal Array and later on the outputs were optimized using ANN and PSO. It was found that the results obtained from both the techniques were tallying with each other.

scholarly journals Analysis of Machining Parameters in WEDM of Al/SiCp20 MMC Using Taguchi-Based Grey-Fuzzy Approach

2019 ◽  
Vol 2019 ◽  
pp. 1-13 ◽  
Author(s):  
Mangesh R. Phate ◽  
Shraddha B. Toney ◽  
Vikas R. Phate
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Machining Parameters ◽  
Peak Current ◽  
Experimental Findings ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed

Aluminium silicate metal matrix composite (AlSiC MMC) is satisfying the requirement of material with good mechanical, thermal properties, and good wear resistance. But the difficulties during the machining are the main hurdles to its replacement for other materials. Wire electric discharge machining (WEDM) is a very effective process used for this type of difficult-to-cut material. So an effort has been taken to find out the most favourable level of input parameters for WEDM of AlSiC (20%) composite using a Taguchi-based hybrid grey-fuzzy grade (GFG) approach. The plan for experimentation is designed using Taguchi’s L9 (23) array. The various process parameters considered for the investigation are pulse on time (TON), pulse off time (TOFF), wire feed rate (WFR), and peak current (IP). Surface integrity such as surface roughness measured during the different types of cutting (along straight, inclined, and curvature directions) is considered in the present work. Grey relational analysis (GRA) pooled with the fuzzy logic is effectively used to find out the grey-fuzzy reasoning grade (GFRG). The Taguchi approach is coupled with the GFRG to obtain the optimum set of process parameters. From the experimental findings, it has been observed that the most economical process parameters for WEDM of AlSiCp20 were the pulse on time is 108 microsec, pulse off time is 56 microsec, wire feed rate (WFR) is 4 m/min, and peak current (IP) is 11 amp. From the analysis of variance (ANOVA), it is observed that the pulse on time is the foremost influencing parameters that contribute towards GFRG by 52.61%, followed by the wire feed rate (WFR) 38.32% and the current by 5.45%.

Identification of Optimal Process Parameters in Electro-Discharge Machining Using ANN and PSO

2022 ◽  
pp. 824-842
Author(s):  
Kaushik Kumar ◽  
J. Paulo Davim
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Repair Work ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Edm Process ◽  
Time Pulse

Electrical Discharge Machining (EDM) process is a widely used machining process in several fabrication, construction and repair work applications. Considering Pulse-On Time, Pulse OFF time, Peak-Current and Gap voltage as the inputs and among all possible outputs, in the present work Material Removal Rate and Surface Roughness are considered as outputs. In order to reduce the number of experiments Design of Experiments (DOE) was undertaken using Orthogonal Array and later on the outputs were optimized using ANN and PSO. It was found that the results obtained from both the techniques were tallying with each other.

Investigations of the Effect of Parameters on the CR and SR during Al6063/SiC/Ti at WEDM

2019 ◽  
Vol 895 ◽  
pp. 181-186
Author(s):  
Rajesh Khanna ◽  
Neeraj Sharma ◽  
Rahul Dev Gupta
Keyword(s):  
Machine Tool ◽  
Process Parameters ◽  
Limited Range ◽  
Machining Process ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

Wire electric discharge machine (WEDM) is a non-conventional machining process used to machine the hard to cut materials. WEDM has wide applications in die and punch industries, automobile, aerospace and medical industries. In this process the material is processed with the help of a wire electrode. In present work, Al6063/SiC/Ti composite was processed with the help of WEDM. As this spark-erosion machine tool have number of input process parameters, so to process any material it became mandatory to investigate the range of the machining parameters in which machine tool operate successfully. Every material represents its unique material characteristics due to which it can be machined successfully in a limited range of the parameters. Above and below this range the wire will break abruptly. So, in this present work an attempt has been made to investigate the range of the process parameters in which WEDM can process Al6063/SiC/Ti composite efficiently. The input parameters considered for the present work are pulse on-time, pulse off-time, servo voltage, peak current, wire feed and wire tension. After the experiments it was found that the pulse on-time, pulse off-time, servo voltage and wire-feed were the significant process parameters in the investigations of cutting rate and surface roughness.

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