Modeling and Optimization of Multi-Performance Characteristics of Powder-Mixed EDM of Tungsten Carbide Alloy Using Intelligent Decision-Making Tools

2017 ◽  
Vol 16 (02) ◽  
pp. 101-128 ◽  
Author(s):  
Jagdeep Singh ◽  
Rajiv Kumar Sharma
Keyword(s):  
Decision Making ◽  
Tungsten Carbide ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Inference System ◽  
Intelligent Decision Making ◽  
Intelligent Decision ◽  
Input Parameters ◽  
Pulse On Time

The main aim of this work is to propose a hybrid framework, which makes use of intelligent decision-making tools, that are gray, fuzzy, and ANFIS, to optimize the multi-performance characteristics (MPCs) of powder-mixed electrical discharge machining (PM-EDM) of tungsten carbide (WC). To perform the experimentation, four input parameters: (i) pulse-on time, (ii) current, (iii) powder concentration, and (iv) powder grain size are considered to investigate the MPCs such as material removal rate, tool wear rate, surface roughness, and micro-hardness. The proposed framework uses response surface methodology (RSM) with gray, gray-fuzzy, and gray-ANFIS approaches to obtain optimal solution and also to handle the element of uncertainty or fuzziness associated with the uncertain, multi-input, and discrete data. This method helps to generate the values of gray relational grade (GRG), gray-fuzzy reasoning grade (GFRG), and gray adaptive neuro-fuzzy inference system grade (G-ANFISG) for all the 30 experiments. Analysis of variance (ANOVA) is performed on GRG, GFRG, and G-ANFISG to identify the major contributing input parameters which may affect the MPCs. Finally, the theoretical prediction is done to verify the improvement in the performance characteristics obtained through the proposed approaches. Both the experimental and statistical results clearly demonstrate the success of proposed framework for the optimization of PM-EDM of WC alloy.

scholarly journals MODELLING AND OPTIMIZATION OF PERFORMANCE CHARACTERISTICS IN ELECTRICAL DISCHARGE MACHINING ON TITANIUM ALLOY

2013 ◽  
Vol 43 (1) ◽  
pp. 33-40
Author(s):  
Md. Ashikur Rahman Khan
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Short Pulse ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Pulse Interval ◽  
Hard Material ◽  
Set Up ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining (EDM) technique possesses noticeable advantages over othermachining process and can machine any hard material effectively. Proper selection of parameters in EDM isvery much essential to achieve better performance characteristics that are still challenging. This study attemptsto investigate the effects of parameters on EDM performance characteristics on Ti-6Al-4V utilizing coppertungsten as electrode and negative polarity of the electrode. Mathematical model associating the influences ofthese variables and the EDM characteristics such as material removal rate (MRR) and tool wear rate (TWR)are set up in this study. The optimal machining conditioning in favor of MRR and TWR are estimated. Design ofexperiments method and response surface methodology techniques are adopted to attain the objectives. Analysisof variance (ANOVA) has been performed for the validity test of the fit and adequacy of the proposed models.Optimum MRR is found at high discharge ampere, long pulse on time and short pulse off time. 8A peak current,10 ?s pulse on time and 184 ?s pulse interval yields lowest TWR. The result of this investigation guides torequired process outputs and economical industrial machining optimizing the input factors.DOI: http://dx.doi.org/10.3329/jme.v43i1.15778

Multi-Response Optimization of Machining Process Parameters for Wire Electrical Discharge Machining of Lead-Induced Ti-6Al-4V Alloy Using AHP–TOPSIS Method

2019 ◽  
Vol 18 (02) ◽  
pp. 213-236 ◽  
Author(s):  
A. V. S. Ram Prasad ◽  
Koona Ramji ◽  
Murahari Kolli ◽  
G. Vamsi Krishna
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Machining Process ◽  
Analytic Hierarchy ◽  
Response Characteristics ◽  
Multi Attribute Decision Making ◽  
Pulse On Time ◽  
Pulse Off Time

In this study, the effects of the process parameters on their performance characteristics of lead-induced Ti-6Al-4V alloy were investigated. Taguchi’s [Formula: see text] orthogonal array (OA) has been used to conduct the experiments. Four process parameters were considered each at three levels. Peak current, pulse-on-time, servo voltage and pulse-off-time were selected as process parameters on performance characteristics, namely, material removal rate (MRR), surface roughness (SR) and dimensional deviation (DD). A multi-attribute decision-making (MADM) technique, namely, analytic hierarchy process (AHP) and technique for order of preference by similarity to ideal solution (TOPSIS), has been used to investigate the multiple response characteristics. The weights for performance characteristics are determined by AHP. Finally, analysis of variance method has been employed effectively to bring out the influence of the process parameters associated with each performance characteristic, namely, maximization of MRR and minimization of SR and DD.

Correlation of Input Parameters with Tool Martial on the Output Parameters of Electrical Discharge Machining Process

2012 ◽  
Vol 445 ◽  
pp. 994-999 ◽  
Author(s):  
Mohammad Reza Shabgard ◽  
Mirsadegh Seyedzavvar
Keyword(s):  
Electrical Discharge ◽  
Material Removal ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Material ◽  
Machining Process ◽  
Process Stability ◽  
Input Parameters ◽  
Pulse On Time

This paper details the correlation between the input parameters with the tool material on the machining response in comparison of two different combinations of toolworkpiece material, namely copper-H13 and graphite-H13. The considered machining input parameters included pulse current and pulse on-time, and the investigated characteristics of the machining response were the material removal rate, tool wear, and surface roughness of the workpiece. Furthermore, differences in pulse shapes and process stability between the copper-H13 and graphite-H13 combinations were investigated.

scholarly journals Experimental Investigation and Optimization of Electric Discharge Machining Process Parameters Using Grey-Fuzzy-Based Hybrid Techniques

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5820
Author(s):  
Ankit Sharma ◽  
Vidyapati Kumar ◽  
Atul Babbar ◽  
Vikas Dhawan ◽  
Ketan Kotecha ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Spheroidal Graphite ◽  
Electrode Gap ◽  
Peak Current ◽  
Hybrid Techniques ◽  
Input Parameters ◽  
Pulse On Time ◽  
Edm Process

Electrical discharge machining (EDM) has recently been shown to be one of the most successful unconventional machining methods for meeting the requirements of today’s manufacturing sector by producing complicated curved geometries in a broad variety of contemporary engineering materials. The machining efficiency of an EDM process during hexagonal hole formation on pearlitic Spheroidal Graphite (SG) iron 450/12 grade material was examined in this study utilizing peak current (I), pulse-on time (Ton), and inter-electrode gap (IEG) as input parameters. The responses, on the other hand, were the material removal rate (MRR) and overcut. During the experimental trials, the peak current ranged from 32 to 44 A, the pulse-on duration ranged from 30–120 s, and the inter-electrode gap ranged from 0.011 to 0.014 mm. Grey relational analysis (GRA) was interwoven with a fuzzy logic method to optimize the multi-objective technique that was explored in this EDM process. The effect of changing EDM process parameter values on responses was further investigated and statistically analyzed. Additionally, a response graph and response table were produced to determine the best parametric setting based on the calculated grey-fuzzy reasoning grade (GFRG). Furthermore, predictor regression models for response characteristics and GFRG were constructed, and a confirmation test was performed using randomly chosen input parameters to validate the generated models.

scholarly journals Experimental investigation of Wire Electrical Discharge Machining (WEDM) Process Parameters on SS304 using Taguchi method

2018 ◽  
Author(s):  
T Vijaya Babu ◽  
B Subbaratnam
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Taguchi’S Method ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

WEDM (Wire Electrical discharge machining) is a nonconventional machining processes used in complicated shapes with high accuracy which are not possible with other conventional methods .Stainless steel 304 is used in present experimental work. Experiments are completed using Taguchi’s method with L9 orthogonal array .The aim of this work is to optimize the WEDM process parameters by considering input parameters are pulse on time , pulse off time ,peak current and wire feed and experiments are conducted with help of input parameters at three levels and response output parameters are MRR (Material removal Rate) and Surface Roughness (SR).Setting of parameters using by Taguchi’s method.

scholarly journals Optimization and modeling of Electrical Discharge parameters on Machining of Stavax Steel

2020 ◽  
Vol 6 (11) ◽  
pp. 53-62
Author(s):  
P Srinivasa Rao and Prof. Eshwara Prasad Koorapati
Keyword(s):  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Linear Regression Analysis ◽  
Performance Characteristics ◽  
Dielectric Fluid ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This work focuses on the use of the Taguchi method in order to find out the optimized parameters of the process like discharge current, pulse on time and pulse off time on the machining features such as material removal rate(MRR), surface roughness(SR) & tool wear rate(TWR) on Stavax Steel by means of Electrical Discharge Machining(EDM). It is also intended to study the individual influence of parameters on the performance characteristics. The dielectric fluid circulating system is modified to conduct the experiments. The analysis of variance (ANOVA) is made to recognise the importance of parameters on the response. By using non-linear regression analysis the empirical models are developed in order to predict these performance characteristics and the confirmation test was conducted at the optimal parameters settings to check the optimum expected values of performance features. Detailed analysis by using ANOVA is done and came out with the findings as a pulse on time is the most significant process parameter, next is the discharge current and the insignificant parameter is the pulse off time. Machining surface morphology was studied and observed that crater size is large and deeper due to a large amount of metal is melted and vaporized at the optimum condition of MRR.

EFFECT OF INPUT PARAMETERS ON THE KEY MACHINABILITY ASPECTS OF NITINOL DURING WEDM

2021 ◽  
Author(s):  
HIMADRI MAJUMDER ◽  
ADIK YADAO ◽  
KALIPADA MAITY
Keyword(s):  
Shape Memory ◽  
Smart Materials ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Mechanical Energy ◽  
Phase Changes ◽  
High Tech ◽  
Machined Surface ◽  
Input Parameters ◽  
Pulse On Time

Shape memory alloy (SMA), a distinctive class of material, can possess its preceding form when subjected to definite thermo-mechanical energy. Nitinol, an SMA, having an admirable shape memory effect, super elastic, and biomechanical properties, has developed a vast application in the field of biomedical, automobile, robotics, aerospace, etc. Wire electrical discharge machining (WEDM) technique is employed for machining of electrically conductive materials like SMAs, high tech ceramics, smart materials, etc. This paper is focused on analyzing the effect of different significant input parameters on the vital machinability aspects of SMA nitinol during WEDM. Independent input variables like pulse-on time ([Formula: see text], discharge current ([Formula: see text], wire-speed (WS), wire tension (WT) and flushing pressure (FP) were considered to find out their influence on the kerf width (KW), material removal rate (MRR), arithmetic mean roughness ([Formula: see text], and microhardness ([Formula: see text]h). 3D optical profile, X-ray diffraction analysis, and scanning electron microscopy were also executed on the WEDMed surface to inspect the surface, microstructure, and phase changes in the machined surface. It was detected that [Formula: see text], [Formula: see text] and FP were more influential than WT and WS for most of the responses.

scholarly journals Optimization of Process Parameters for Minimum Surface Roughness in Wire Electrical Discharge Machining of AISI 1045 Steel Using Taguchi Method

2021 ◽  
Vol 9 (10) ◽  
pp. 989-997
Author(s):  
Rouhan Rafiq
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time

Abstract: One of the important non-traditional machining processes is Wire Electrical Discharge Machining, used for machining difficult to machine materials like composites and inter-metallic materials. WEDM involves complex physical and chemical process including heating and cooling. Accompanying the development of mechanical industry, the demand for alloy materials having high hardness, toughness and impact resistance are increasing. The WEDM satisfy the present demands of the manufacturing industries such as better finish, low tolerance, higher production rate, miniaturization etc. The consistent quality of parts being machined in WEDM is difficult because the process parameters cannot be controlled effectively. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researcher and practicing engineers for a very long time. The objective of the present study was to experimentally investigate the effects of various Wire Electrical Discharge Machining variables on Surface Roughness and Material Removal Rate of AISI 1045 using ANOVA method. Taguchi’s L18 Orthogonal Array was used to conduct experiments, which correspond to randomly chosen different combination of process parameters: wire type, pulse on time, pulse off time, peak current, servo voltage, wire feed rate, flushing pressure each to be varied in three different levels. The surface roughness and material removal rate were selected as output responses for the present investigation. The effect of all the input parameters on the output responses have been analyzed using analysis of variance (ANOVA). The effect of variation in input parameters has been studied on the output responses. Plots of S/N ratio have been used to determine the best relationship between the responses and the input parameters. In other words, the optimum set of input parameters for minimum surface roughness and maximum material removal rate were determined. It has been found that wire type, pulse on time are most significant factors for surface roughness and wire type, pulse on time, pulse off time, wire feed rate are most significant factors for material removal rate. Keywords: Input Parameters, Wire Electric Discharge Machining, ANOVA, Taguchi

Effect of Powder-Mixed Dielectric on EDM Process Performance

2020 ◽  
Vol 38 (8A) ◽  
pp. 1226-1235
Author(s):  
Safa R. Fadhil ◽  
Shukry. H. Aghdeab
Keyword(s):  
Silicon Carbide ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Speed Steel ◽  
Transformer Oil ◽  
Dielectric Fluid ◽  
Peak Current ◽  
Powder Concentration ◽  
Pulse On Time

Electrical Discharge Machining (EDM) is extensively used to manufacture different conductive materials, including difficult to machine materials with intricate profiles. Powder Mixed Electro-Discharge Machining (PMEDM) is a modern innovation in promoting the capabilities of conventional EDM. In this process, suitable materials in fine powder form are mixed in the dielectric fluid. An equal percentage of graphite and silicon carbide powders have been mixed together with the transformer oil and used as the dielectric media in this work. The aim of this study is to investigate the effect of some process parameters such as peak current, pulse-on time, and powder concentration of machining High-speed steel (HSS)/(M2) on the material removal rate (MRR), tool wear rate (TWR) and the surface roughness (Ra). Experiments have been designed and analyzed using Response Surface Methodology (RSM) approach by adopting a face-centered central composite design (FCCD). It is found that added graphite-silicon carbide mixing powder to the dielectric fluid enhanced the MRR and Ra as well as reduced the TWR at various conditions. Maximum MRR was (0.492 g/min) obtained at a peak current of (24 A), pulse on (100 µs), and powder concentration (10 g/l), minimum TWR was (0.00126 g/min) at (10 A, 100 µs, and 10 g/l), and better Ra was (3.51 µm) at (10 A, 50 µs, and 10 g/l).

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