Optimization of process parameters in magnetic field assisted powder mixed EDM of aluminium 6061 alloy

2020 ◽  
pp. 095440622095910
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Discharge Current ◽  
Electrical Discharge Machining ◽  
Desirability Function ◽  
Fine Powder ◽  
Quadratic Model ◽  
Electrode Wear

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is a variant of EDM process where magnetic field coupled with electric field is used with addition of fine powder in dielectric to improve the surface quality, machining rate and stability of the process. Aluminium 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In this present work, parametric study and optimization was carried out on MFAPM-EDM machined Aluminium 6061 alloy. In this study, process parameters such as discharge current (IP), spark duration (PON), pause duration (POFF), concentration of powder (CP) and magnetic field (MF) were considered to analyze the effect on material erosion rate (MER) and electrode wear rate (EWR). Box Behnken design approach based on response surface methodology (RSM) was utilized for performing the experiments. Quadratic model to predict the MER and EWR were developed using response surface methodology. Discharge current has most significant effect of 50.176% and 36.36% on MER and EWR, respectively among all others process parameters. Teacher-learning-based optimization (TLBO) was employed for determining the optimal process parameters for maximum MER and minimal EWR. The results obtained with TLBO was compared with well-known optimization methods such as genetic algorithm (GA) and desirability function of RSM. Minimum EWR (0.1021 mm3/min) and maximum MER (30.4687 mm3/min) obtained using TLBO algorithm for optimized process parameters was found to better as compared to GA and desirability function.

scholarly journals Multi-response optimization of magnetic field assisted EDM through desirability function using response surface methodology

2020 ◽  
Vol 29 (1) ◽  
pp. 19-35
Author(s):  
Anish Kumar ◽  
Renu Sharma
Keyword(s):  
Magnetic Field ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Performance Measures ◽  
Process Parameters ◽  
Removal Rate ◽  
Desirability Function ◽  
Surface Model ◽  
Electrode Wear ◽  
En 31

AbstractMagnetic field assisted electrical discharge machining (MFAEDM) is the modification of in conventional EDM process by use of magnetic field on EN-31. This article explain the application of response surface methodology to analyzes the effect of various process parameters such as Ton, Toff and Ip on performance measures such as material removal rate (MRR), electrode wear rate (EWR) and overcut (OC). Analysis of variance was used to check the adequacy of response surface model and significance of process parameters on performance measures. Multi-objective desirability function has been applied to obtain the optimal process parameter settings. Thereafter, machined surface of EN-31 characterized through SEM and EDX. The novelty of this paper is to improve the strategies for flushing the debris which remain clogged in standard EDM in-between machining gap that will interrupts the regular discharge conditions and reduces cutting rate as well as deteriorate the surface characteristics.

Multi-objective Optimization of UV Spot Curing Technique of Slider - Suspension Attachment Process Using Response Surface Methodology Approach

2021 ◽  
Author(s):  
Santi Pumkrachang
Keyword(s):  
Response Surface Methodology ◽  
Shear Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Epoxy Adhesive ◽  
Quadratic Model ◽  
Uv Curable ◽  
Multi Objective ◽  
Validation Experiment ◽  
Cure Time

The ultraviolet (UV) curing of slider-suspension attachment is going to change from a manual to an automated process. As a result, the bonding parameters of adhesive between slider and suspension needs to be optimized. This paper aims to study two output responses of the UV curable epoxy adhesive i.e., shear strength force and pitch static attitude (PSA) of the joint between slider and suspension in a head gimbal assembly (HGA). Four process parameters were investigated using response surface methodology (RSM) based on face-centered central composite design (FCCD). The RSM was applied to establish a mathematical model to correlate the significance of process parameters and the responses. Then the based multi-objective was applied to determine a quadratic model and obtained the output maximization at 224 g of shear strength force and PSA value close to the target at 1.8 degrees. The input process parameters were optimized at 0.7 s of UV bottom cure time, 120 °C of UV dual side temperature, 5.0 s of UV dual side cure time, and 230 μm of adhesive dot size. The validation experiment showed a prediction response error of less than 7% of the actual value.

Multi-Performance Optimization in Friction Stir Welding of Aluminum Alloy Using Response Surface Methodology

2018 ◽  
pp. 240-263
Author(s):  
Rajat Gupta ◽  
Kamal Kumar ◽  
Neeraj Sharma
Keyword(s):  
Response Surface Methodology ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Response Surface ◽  
Process Parameters ◽  
Performance Optimization ◽  
Desirability Function ◽  
High Carbon Steel ◽  
Friction Stir ◽  
Tool Shoulder

This chapter presents the friction stir welding (FSW) of aluminum alloy AA-5083-O using vertical milling machine. In present FSW experimentation, effects of different process parameter namely tool rotation speed, welding speed, tool geometry, and tool shoulder diameter have been determined on welding quality of two pieces of AA-5083-O using response surface methodology (RSM). The optimal sets of process parameters have been determined for weld quality characteristics namely tensile strength (UTS) and percentage elongation (%EL). In present experimentations, a specially designed tool made of high carbon steel with different shoulder diameters (15mm, 17.5mm, and 20 mm) having constant pin length (6 mm) were used for FSW of two pieces of aluminum alloy. The ANOVA and pooled ANOVA were used to study the effect of FSW parameters on UTS and %EL. Multi response optimization has been carried out using desirability function in conjunction with RSM to obtain the optimal setting of process parameters for higher UTS and lower %EL.

scholarly journals Effect of Terminalia catappa Leaves Extract on Corrosion of Mild Steel using Response Surface Methodology

2020 ◽  
Vol 27 (2) ◽  
pp. 47-56
Author(s):  
A.O. Okewale ◽  
O.A. Adesina ◽  
B.H. Akpeji
Keyword(s):  
Response Surface Methodology ◽  
Mild Steel ◽  
Response Surface ◽  
Inhibition Efficiency ◽  
Desirability Function ◽  
Inhibitory Effect ◽  
Quadratic Model ◽  
Box Behnken Design ◽  
Terminalia Catappa ◽  
Maximum Inhibition

Effect of Terminalia catappa leaves (TCL) extract in inhibiting corrosion of mild steel was investigated. In order to obtain the maximum inhibition efficiency, optimization of the process variables affecting corrosion of mild steel was carried out using the Box – Behnken Design plan and desirability function of Response Surface Methodology (RSM). The three parameters - varied include; TCL concentration (inhibitor), immersion time, and temperature and there effects in corrosion inhibition were established. The optimum conditions predicted from the quadratic model were inhibitor’s concentratrion (0.39 g/l), exposure time (8.68 hours), and temperature (36.06 oC) with the inhibition efficiency of 91.95 %. The data fitted well to the quadratic model which was validated. Adsorption of the extract’s component on the mild steel was responsible for the inhibitory effect of the TCL extract.The results showed that 97.92% of the total variation in the inhibition efficiency of TCL can be connected to the variables studied. Keywords: Mild steel, acid, Terminalia catappa, Corrosion, Response surface methodology (RSM).

scholarly journals Optimization Study of Biomass Hydrogenation to Ethylene Glycol Using Response Surface Methodology

Processes ◽  
2020 ◽  
Vol 8 (5) ◽  
pp. 588
Author(s):  
Poh Gaik Law ◽  
Noor Haida Sebran ◽  
Ashraf Zin Zawawi ◽  
Azlan Shah Hussain
Keyword(s):  
Response Surface Methodology ◽  
Ethylene Glycol ◽  
Response Surface ◽  
Process Parameters ◽  
Quadratic Function ◽  
Quadratic Model ◽  
Coefficient Of Determination ◽  
Mass Ratio ◽  
Empty Fruit Bunches ◽  
Binary Catalyst

Statistical-based study using response surface methodology (RSM) was conducted to study the effects of process parameters towards biomass hydrogenation. Using Malaysian oil palm empty fruit bunches (EFB) fibres as feedstock, the central composite design (CCD) technique was employed and 18 runs were generated by CCD when four parameters (mass ratio of binary catalyst, hydrogen pressure, temperature and mass ratio of catalyst to feedstock) were varied with two center points to determine the effects of process parameters and eventually to get optimum ethylene glycol (EG) yield. RSM with quadratic function was generated for biomass hydrogenation, indicating all factors except temperature, were important in determining EG yield. Analysis of variance (ANOVA) showed a high coefficient of determination (R2) value of >0.98, ensuring a satisfactory prediction of the quadratic model with experimental data. The quadratic model suggested the optimum EG yield should be >25 wt.% and the EG yield results were successfully reproduced in the laboratory.

scholarly journals Application of response surface methodology for color removing from dyeing effluent using de-oiled activated algal biomass

2021 ◽  
Vol 45 (1) ◽  
Author(s):  
Samar A. El-Mekkawi ◽  
Rehab A. Abdelghaffar ◽  
Fatma Abdelghaffar ◽  
S. A. Abo El-Enin
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Industrial Development ◽  
Industrial Effluents ◽  
Quadratic Model ◽  
Activation Process ◽  
Prime Concern ◽  
Desirability Approach ◽  
Dyeing Effluent

Abstract Background Conservation of the ecosystem is a prime concern of human communities. Industrial development should adopt this concern. Unfortunately, various related activities release lots of noxious materials concurrently with significant leakage of renewable resources. This work presents a new biosorbent activated de-oiled microalgae, Chlorella vulgaris, (AC) for biosorption of Acid Red 1 (AR1) from aqueous solution simulated to textile dyeing effluent. The biosorption characteristics of AC were explored as a function of the process parameters, namely pH, time, and initial dye concentration using response surface methodology (RSM). Results Optimization is carried out using the desirability approach of the process parameters for maximum dye removal%. The ANOVA analysis of the predicted quadratic model elucidated significant model terms with a regression coefficient value of 0.97, F value of 109.66, and adequate precision of 34.32 that emphasizes the applicability of the model to navigate the design space. The optimization depends on the priority of minimizing the time of the process to save energy and treating high concentrated effluent resulted in removal % up to 83.5%. The chemical structure and surface morphology of AC, and the dye-loaded biomass (AB) were characterized by Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), energy-dispersive X-ray analysis (EDX), and transmission electron microscope (TEM). The activation process transforms the biomass surface into a regular and small homogeneous size that increases the surface area and ultimately enhances its adsorption capacity Conclusion The optimization of the process parameters simultaneously using RSM performs a high-accurate model which describes the relationship between the parameters and the response through minimum number of experiments. This study performed a step towards an integrated sustainable solution applicable for treating industrial effluents through a zero-waste process. Using the overloaded biomass is going into further studies as micronutrients for agricultural soil.

Semi-empirical modeling and optimization of process parameters on overcut during MFAPM-EDM of Al6061 alloy

2021 ◽  
pp. 095440892110158
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Process Parameters ◽  
Empirical Model ◽  
Discharge Current ◽  
Desirability Function ◽  
Experimental Results ◽  
Empirical Modeling ◽  
Machining Process ◽  
Optimum Process ◽  
Semi Empirical

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) process is a hybrid process machining process which improves the machining characteristics and stability of process using assistive magnetic field and dielectric admixed powder. In this article, study on overcut has been performed on MFAPM-EDM machined Aluminium 6061 alloy. Discharge current, powder concentration, pulse on duration, pulse off duration, and magnetic field strength as process parameters have been varied during experimentation. Box Behnken design approach was employed for experimental design to carry out the experiments. Suitable Semi-empirical model was formulated using dimensional analysis for predicting the overcut. The empirical model developed was also compared with RSM model and was found better in predicting the response. Optimum process parameters for minimal overcut was conducted desirability function approach of RSM. Experimental results divulged discharge current as the most important parameters for overcut as compared to other process parameters on account of higher F-value. Confirmatory experiments revealed good correlation between optimum and experimental results.

scholarly journals Optimization of the Material Removal Rate and Electrode Wear Ratio in Electrical Discharge Machining of Reaction-bonded Silicon Carbide by Response Surface Methodology

2020 ◽  
Vol 9 (4) ◽  
pp. 2116-2120
Keyword(s):  
Silicon Carbide ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Hardness ◽  
Electrode Wear ◽  
Good Surface ◽  
Pulse On Time

Reaction-bonded silicon carbide (RB-SiC) is widely used as moulding dies material in many industries thanks to its excellent properties. Nevertheless, because of its high hardness and brittleness, it is extremely hard to be machined with high accuracy and good surface finish. Therefore, electrical discharge machining (EDM) has been chosen as an alternative method to machine the RB-SiC. In the present study, an experimental investigation has been conducted to optimize and validate the EDM parameters on the MRR and EWR of low conductivity RB-SiC in EDM. The new Cu – 1.0 wt. % CNF composite electrode that fabricated via powder metallurgy (PM) process was used as the electrode. The experiments were systematically conducted by face-cubic centre (FCC) approach of response surface methodology (RSM). The mathematical models for MRR and EWR were developed in this study. In addition, analysis of variance (ANOVA) was also figured out to check the significance of the models. Three experiments were conducted as the confirmation test to determine the error percentage of MRR and EWR. Based on the results, only 3.06% and 3.93% errors were determined for both MRR and EWR, respectively. The optimum conditions for multi responses (MRR and EWR) were found to be at a current of 6A, voltage of 22V, and pulse on-time of 12µs. The findings of this study provide an important reference to the manufacturing industries, especially mould and die industry.

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