Optimization of EDM Hole Drilling Parameters in Machining of MoSi2-SiC Intermetallic/Composites for Improving Geometrical Tolerances

2015 ◽  
Vol 14 (04) ◽  
pp. 259-272 ◽  
Author(s):  
L. Selvarajan ◽  
C. Sathiya Narayanan ◽  
R. Jeyapaul
Keyword(s):  
Ceramic Composites ◽  
Performance Characteristics ◽  
Drilling Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
New Approach ◽  
Drilling Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing

Intermetallic/ceramic composites with multiple responses are based on L18 orthogonal array with gray relational analysis (GRA). This paper presents a new approach for the optimization of drilling parameters on drilling MoSi 2– SiC composites. Optimal machining parameters can then be determined by the gray relational grade as the performance index. In this study, the sparking parameters namely current (I), pulse on time (t on ), pulse off time (t off ), spark gap and dielectric flushing pressure (P) are optimized with considerations of multiple performance characteristics including multi responses such as material removal rate (MRR), electrode wear rate (EWR), circularity (CIR), cylindricity (CYL), perpendicularity (PER). A gray relational grade obtained from the GRA is used to solve the electrical discharge machining (EDM) process with the multiple performance characteristics. Based on the gray relational grade, optimum levels of parameters have been identified and significant contribution of parameters is determined by ANOVA. Confirmation test is conducted to validate the test result. Experimental results have shown that the responses in EDM drilling process can be improved effectively through the new approach.

Multiple Performance Optimization in WEDM Parameters Using Grey Relational Analysis

2015 ◽  
Vol 813-814 ◽  
pp. 357-361
Author(s):  
T. Rajmohan ◽  
Gopi Krishna ◽  
Ankit Kumar Singh ◽  
A.P.V. Swamy Naidu
Keyword(s):  
Grey Relational Analysis ◽  
Performance Characteristics ◽  
304L Stainless Steel ◽  
Machining Parameters ◽  
Relational Analysis ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Off Time

In this investigation, a new approach is based on Grey Relational Analysis and Taguchi method to optimize the machining parameters with multi performance characteristics in WEDM of 304L SS. Experiments are conducted using Taguchi Quality Concept, L9,3-level orthogonal array was chosen for experiments .The WEDM parameters namely pulse-on time (TON), pulse-off time (TOFF), and wire feed (WF) on material removal rate (MRR) .The Grey Relational Analysis with multiple performance characteristics indicates that the pulse-on time (TON), pulse-off time (TOFF) are the most significant factors . The optimum machining parameters have been identified by Grey relational analysis and significant contribution of parameters can be determined by analysis of variance (ANOVA). The confirmation test is also conducted to validate the test result. The results from this study will be useful for manufacturing engineers to select appropriate WEDM process parameters to machine 304L Stainless Steel.

The Effect of EDM Die-Sinking Parameters on Machining Characteristics in Aluminum Alloy Machining

2015 ◽  
Vol 761 ◽  
pp. 303-307 ◽  
Author(s):  
Laily Suraya ◽  
M.A. Ali ◽  
N.I.S. Hussein ◽  
Mohd Razali Muhamad ◽  
Manshoor Bukhari ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Design Matrix ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Electrode Tool ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Machining Characteristics

The effect of machining parameters on machining characteristics for aluminium alloy LM6 (Al-Sil2) in Electrical Discharge Machining (EDM) die-sinking is studied. The objective of this project is to determine the relationship between the machining parameters including pulse-on time, pulse-off time, peak current and voltage with the machining characterictics such as Material Removal Rate (MRR), Electrode Wear Rate (EWR) and Surface Roughness (Ra). Copper materials having diameter 15mm was chosen as the electrode tool. Design of experimenent using Taguchi technique was employed to design experimental matrix that was used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that current and pulse off time significantly affect MRR, EWR and Ra while pulse on time and voltage are less significant in their effect on machining responses. Results show that using Taguchi as a design matrix, the best setting of optimum value for machining parameters to find the required machining responses can be obtained.

Performance Measurement and Data Analysis of Material Removal Rate for Wire Cut Electro Discharge Machining Process

2011 ◽  
Vol 110-116 ◽  
pp. 1683-1690 ◽  
Author(s):  
Vishal Parashar ◽  
A. Rehman ◽  
J.L. Bhagoria
Keyword(s):  
Regression Analysis ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Performance Criteria ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing

In this paper, statistical and regression analysis of material removal rate using design of experiments is proposed for WEDM operations. Experimentation was planned as per Taguchi’s mixed orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, pulse OFF time, wire feed and dielectric flushing pressure. Stainless Steel grade 304L was selected as a work material to conduct the experiments. From experimental results, the material removal rate was determined for each machining performance criteria. Analysis of variance (ANOVA) technique was used to find out the variables affecting the material removal rate. Assumptions of ANOVA were discussed and carefully examined using analysis of residuals. Variation of the material removal rate with machining parameters was mathematically modeled by using the regression analysis method. The developed model was validated with a set of experimental data and appeared to be satisfactory. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method.

The Effect of EDM Die-Sinking Parameters on Material Characteristic for Aluminum Composite

2014 ◽  
Vol 699 ◽  
pp. 26-31 ◽  
Author(s):  
Mohd Amran Ali ◽  
Laily Suraya ◽  
Nor Atiqah Jaffar Sidek ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Aluminum Composite ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The machining ability of Electrical Discharge Machining (EDM) die-sinking on material characteristics of LM6 (Al-Sil2) is studied. This is due to the machining process on sharp edge, pocket, deep slot and micro hole cannot be performed by milling and turning machine. The objective of this paper is to determine the relationship between the machining parameters such as pulse on time, pulse off time, peak current and voltage on material removal rate (MRR) that are electrode wear rate (EWR) and surface roughness (Ra). Graphite tool of diameter 15mm was chosen as an electrode. Taguchi method is used as analysis technique to develop experimental matrix that is used to optimize the MRR, EWR and Ra. The analysis was done by using the Minitab software version 16. It is found that the current and pulse off time are significantly effected the MRR, EWR and Ra while pulse on time and voltage are less significant factors that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

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.

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

Multi-Objective Optimization of EDM Parameters Using Grey Relational Analysis for Titanium Alloy (Ti–6Al–4V)

2014 ◽  
Vol 592-594 ◽  
pp. 540-544 ◽  
Author(s):  
A. Palanisamy ◽  
R. Rekha ◽  
S. Sivasankaran ◽  
C. Sathiya Narayanan
Keyword(s):  
Grey Relational Analysis ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Relational Analysis ◽  
Grey Relational Grade ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

In this paper optimization of the electrical discharge machining (EDM) process with multiple performance characteristics based on the orthogonal array with the grey relational analysis was studied and investigated. A grey relational grade obtained from the grey relational analysis is used to solve the EDM process. Optimal machining parameters are determined by considering the grey relational grade as the performance index. The input independent parameters of peak current, pulse on time and pulse off time were examined and optimized on multiple response characters (material removal rate, electrode wear ratio and surface roughness). Experimental results have shown that machining performance in the EDM process can be improved effectively through this approach.

The Effect of EDM Die-Sinking Parameters on Material Characteristic for Aluminium Composite Using Tungsten Copper Electrode

2013 ◽  
Vol 465-466 ◽  
pp. 1214-1218 ◽  
Author(s):  
Mohd Amran Ali ◽  
Laily Suraya ◽  
Halida Ilyani Kamarudin Nor ◽  
Nur Izan Syahriah Hussein ◽  
Mohd Razali Muhamad ◽  
...  
Keyword(s):  
Taguchi Method ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
New Material ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The machining ability of electrical discharge machining (EDM) die-sinking on aluminium LM6 (Al-Sil2) as a new material is investigated.The objective of this paper is to determine the relationship between the machining parameters which are pulse-on time, pulse-off time and peak current on the material characteristics such as material removal rate (MRR), electrode wear rate (EWR) and surface roughness (Ra). Tungsten copper tool of diameter 10mm was chosen as an electrode. Design of experiment using Taguchi method was used to develop experimental matrix and optimize the MRR, EWR and Ra. The analysis was done using the Minitab software. It is found that the current and pulse on time are significantly affected the MRR, EWR and Ra while pulse off time and voltage are less significant factor that affected the responses. From the Taguchi method, the best setting of optimum value was obtained. Thus, it shows that Taguchi method is the best quality tools that can be applied for production.

Optimization of Machining Characteristics in EDM of Si3N4-TiN Composites by Taguchi Grey Relational Analysis

2014 ◽  
Vol 592-594 ◽  
pp. 600-604 ◽  
Author(s):  
L. Selvarajan ◽  
C. Sathiya Narayanan ◽  
R. Jeyapaul
Keyword(s):  
Removal Rate ◽  
Experimental Studies ◽  
Electrode Wear ◽  
Characteristic Features ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing ◽  
Machining Parameter ◽  
Grey Relation

In this study, Sparking parameters specifically Current (I), pulse on time (ton), pulse off time (toff), spark gap and dielectric flushing pressure (P) are optimized with the consideration of multi responses such as Material Removal Rate (MRR) and Electrode wear Rate (EWR). The characteristic features of the Spark EDM process are explored through Taguchi L18 orthogonal array design of experimental studies with various process parametric combinations. To optimize the above machining parameter, grey relation techniques are used. Based on the grey relation grade, optimum levels of parameters have been identified and major contribution of parameters is determined by ANOVA. Verification test is conducted to validate the test result.

Multi-Objective Optimization on Electric Discharge Machining Using by Grey Relational Analysis

2014 ◽  
Vol 592-594 ◽  
pp. 550-554
Author(s):  
L. Selvarajan ◽  
C. Sathiya Narayanan ◽  
R. Jeyapaul
Keyword(s):  
Ceramic Composite ◽  
Removal Rate ◽  
Electrode Wear ◽  
Electric Discharge Machining ◽  
Grey Relational Grade ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Dielectric Flushing ◽  
Off Time

The present study ,Sparking parameters namely current (I), pulse on time (ton), pulse off time (toff), spark gap and dielectric flushing pressure (P) are optimized with the considerations of multi responses such as Material Removal Rate (MRR), Electrode wear Rate (EWR), of the MoSi2-SiC intermetallic/ceramic composite are investigated by use of the Taguchi L18 orthogonal array (OA) with grey relational grade analysis was reported.

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