Investigation of the WEDM of Al/B4C/Gr reinforced hybrid composites using the Taguchi method and response surface methodology

2016 ◽  
Vol 23 (4) ◽  
pp. 435-445 ◽  
Author(s):  
Ali Riza Motorcu ◽  
Ergün Ekici ◽  
Abdil Kuş
Keyword(s):  
Response Surface Methodology ◽  
Taguchi Method ◽  
Response Surface ◽  
Hybrid Composites ◽  
Machining Parameters ◽  
Contribution Ratio ◽  
Control Factors ◽  
Pulse On Time ◽  
Pulse Off Time

AbstractIn this study, the effects of machining parameters on the material removal rate (MRR) and surface roughness (Ra) were investigated during the cutting of Al/B4C/Gr hybrid composites by wire electrical discharge machining (WEDM). Wire speed (WS), pulse-on time (Ton) and pulse-off time (Toff) were chosen as the control factors. The L27 (33) orthogonal array in the Taguchi method was used in the experimental design and for the determination of optimum control factors. Response surface methodology was also used to determine interactions among the control factors. Variance analysis (ANOVA) was applied in the determination of the effects of control factors on the MRR and Ra. According to the ANOVA results, the most effective parameters on MRR and Ra were wire speed with a 85.94% contribution ratio, and pulse-on-time with a 47.7% contribution ratio. The optimum levels of the control factors for MRR and Ra were determined as A3B3C3 and A1B1C2. In addition, second-order predictive models were developed for MRR and Ra; correlation coefficients (R2) were calculated as 0.992 and 0.63.

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).

scholarly journals Study of wire-electrical discharge machining parameters of titanium alloy by using taguchi method

2018 ◽  
Vol 7 (2.8) ◽  
pp. 10
Author(s):  
A VS Ram Prasad ◽  
Koona Ramji ◽  
B Raghu Kumar
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Optimization Technique ◽  
Machining Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Machining of Titanium alloys is difficult due to their chemical and physical properties namely excellent strength, chemical reactivity and low thermal conductivity. Traditional machining of such materials leads to formation of continuous chips and tool bits are subjected to chatter which leads to formation of poor surface on machined surface. In this study, Wire-EDM one of the most popular unconventional machining process which was used to machine such difficult-to-cut materials. Effect of Wire-EDM process parameters namely peak current, pulse-on- time, pulse-off-time, servo voltage on MRRand SR was investigated by Taguchi method. 0.25 mm brass wire was used in this process as electrode material. A surface roughness tester (Surftest 301) was used to measure surface roughness value of the machined work surface. A multi-response optimization technique was then utilized to optimize Wire-EDM process parameters for achieving maximum MRR and minimum SR simultaneously.

scholarly journals Prediction of Machining Characteristics of Hybrid Composites Using Response Surface Methodology Approach

2018 ◽  
Vol 7 (3.1) ◽  
pp. 162 ◽  
Author(s):  
Ramanan. G ◽  
Rajesh Prabha.N ◽  
Diju Samuel.G ◽  
Jai Aultrin. K. S ◽  
M Ramachandran
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Hybrid Composites ◽  
Removal Rate ◽  
Cutting Speed ◽  
Chemical Properties ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Parameters ◽  
Rsm Technique

This manuscript presents the influencing parameters of CNC turning conditions to get high removal rate and minimal response of surface roughness in turning of AA7075-TiC-MoS2 composite by response surface method. These composites are particularly suited for applications that require higher strength, dimensional stability and enhanced structural rigidity. Composite materials are engineered materials made from at least two or more constituent materials having different physical or chemical properties. In this work seventeen turning experiments were conducted using response surface methodology. The machining parameters cutting speed, feed rate, and depth of cut are varied with respect to different machining conditions for each run. The optimal parameters were predicted by RSM technique. Turning process is studied by response surface methodology design of experiment. The optimal parameters were predicted by RSM technique. The most influencing process parameter predicted from RSM techniques in cutting speed and depth of cut.   

Optimization of Machining Parameters on Surface Roughness in EDM of Ti-6Al-4V Using Response Surface Method

2011 ◽  
Vol 213 ◽  
pp. 402-408 ◽  
Author(s):  
M.M. Rahman ◽  
Md. Ashikur Rahman Khan ◽  
M.M. Noor ◽  
K. Kadirgama ◽  
Rosli A. Bakar
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Surface Finish ◽  
Machining Parameters ◽  
Surface Method ◽  
Superior Surface ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This paper presents the influence of EDM parameters in terms of peak ampere, pulse on time and pulse off time on surface roughness of titanium alloy (Ti-6Al-4V). A mathematical model for surface finish is developed using response surface method (RSM) and optimum machining setting in favor of surface finish are evaluated. Design of experiments (DOE) techniques is implemented. Analysis of variance (ANOVA) has been performed to verify the fit and adequacy of the developed mathematical models. The acquired results yield that the increasing pulse on time causes fine surface till a certain value and then deteriorates the surface finish. It is investigated that about 200 µs pulse off time produce superior surface finish. These results lead to desirable surface roughness and economical industrial machining by optimizing the input parameters.

scholarly journals Relevance Vector Machine Based Analyses of MRR and SR of Electrodischarge Machining Designed by Response Surface Methodology

2013 ◽  
Vol 2013 ◽  
pp. 1-9 ◽  
Author(s):  
Kanhu Charan Nayak ◽  
Rajesh Kumar Tripathy ◽  
Sudha Rani Panda
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Duty Cycle ◽  
Discharge Current ◽  
Removal Rate ◽  
Relevance Vector Machine ◽  
Machining Process ◽  
Machining Parameters ◽  
Electrodischarge Machining ◽  
Pulse On Time

Relevance vector machine is found to be one of the best predictive models in the area of pattern recognition and machine learning. The important performance parameters such as the material removal rate (MRR) and surface roughness (SR) are influenced by various machining parameters, namely, discharge current (Ip), pulse on time (Ton), and duty cycle (tau) in the electrodischarge machining process (EDM). In this communication, the MRR and SR of EN19 tool steel have been predicted using RVM model and the analysis of variance (ANOVA) results were performed by implementing response surface methodology (RSM). The number of input parameters used for the RVM model is discharge current (Ip), pulse on time (Ton), and duty cycle (tau). At the output, the corresponding model predicts both MRR and SR. The performance of the model is determined by regression test error which can be obtained by comparing both predicted MRR and SR from model and experimental data is designed using central composite design (CCD) based RSM. Our result shows that the regression error is minimized by using cubic kernel function based RVM model and the discharge current is found to be one of the most significant machining parameters for MRR and SR from ANOVA.

Optimization of WEDM Process Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The objective of the present work is to investigate the effects of various WEDM process parameters like pulse on time, pulse off time, corner servo, flushing pressure, wire feed rate, wire tension, spark gap voltage and servo feed on the material removal rate (MRR) & Surface Roughness (SR) and to obtain the optimal settings of machining parameters at which the material removal rate (MRR) is maximum and the Surface Roughness (SR) is minimum in a range. In the present investigation, Inconel 825 specimen is machined by using brass wire as electrode and the response surface methodology (RSM) is for modeling a second-order response surface to estimate the optimum machining condition to produce the best possible response within the experimental constraints.

OPTIMIZATION OF ELECTRICAL DISCHARGE MACHINING PARAMETERS OF SISIC THROUGH RESPONSE SURFACE METHODOLOGY

2016 ◽  
Vol 79 (1) ◽  
Author(s):  
Abdul Azeez Abdu Aliyu ◽  
Jafri Mohd Rohani ◽  
Ahmad Majdi Abdul Rani ◽  
Hamidon Musa
Keyword(s):  
Silicon Carbide ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Machining Parameters ◽  
Difficult Time ◽  
Pulse On Time

In recent years, researchers have demonstrated increases interest in studies involving silicon carbide (SiC) materials due to several industrial applications. Extreme hardness and high brittleness properties of SiC make the machining of such material very difficult, time consuming and costly. Electrical discharge machining (EDM) has been regarded as the most viable method for the machining of SiC. The mechanism of EDM process is complex. Researchers have acknowledged a challenge in generating a model that accurately describes the correlation between the input parameters and the responses. This paper reports the study on parametric optimization of siliconized silicon carbide (SiSiC) for the following quality responses; material removal rate (MRR), tool wear ratio (TWR) and surface roughness (Ra). The experiments were planned using Face centered central composite design. The models which related MRR, TWR and Ra with the most significant factors such as discharge current (Ip), pulse-on time (Ton), and servo voltage (Sv) were developed. In order to develop, improve and optimize the models response surface methodology (RSM) was used. Non-linear models were proposed for MRR and Ra while linear model was proposed for TWR. The margin of error between predicted and experimental values of MRR, TWR and Ra are found within 6.7, 5.6 and 2.5% respectively. Thus, the excellent reproducibility of this experimental study is confirmed, and the models developed for MRR, TWR and Ra are justified to be valid by the confirmation tests.

Experimental Analysis of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Method

2015 ◽  
Vol 799-800 ◽  
pp. 343-350
Author(s):  
Rahul Shukla ◽  
Brajesh Kumar Lodhi
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Kerf Width ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. In the present work, an attempt has been made to optimization the machining conditions for maximum material removal rate, minimise kerf width based on (L9 Orthogonal Array) Taguchi method. Experiments, based on Taguchi’s parameters design, were carried out to effect of machining parameters, like pulse-on-time (TON), pulse-off-time (TOFF), peak current (IP), and wire feed (WF) on the material removal rate and kerf width. The importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA). The variation of MRR and kerf width with cutting parameters is modeled by using a regression analysis method.

RSM Modeling and Taguchi Analysis of EDM of B4C and Flyash Reinforced Hybrid Nanocomposites

2019 ◽  
Vol 801 ◽  
pp. 227-232
Author(s):  
Sweety Mahanta ◽  
M. Chandrasekaran ◽  
Sutanu Samanta
Keyword(s):  
Taguchi Method ◽  
Performance Measures ◽  
Research Work ◽  
Close Relation ◽  
Hybrid Nanocomposites ◽  
Dominant Factor ◽  
Machining Parameters ◽  
Metal Matrix Nanocomposites ◽  
Pulse On Time ◽  
Pulse Off Time

In this research work, EDM investigation of Al7075-B4C-flyash hybrid metal matrix nanocomposites (HMMNCs) was performed. Taguchi method was used to improve the machinability coupled with response surface methodology (RSM) to estimate the relationship between the machining parameters and performance measures. Experiments were conducted using the L18 full-factorial design with a mixed orthogonal array. Analysis of variance (ANOVA) was used to determine the effects of the machining parameters viz. voltage (V), current (I), pulse-on-time (Ton) and pulse-off-time (Toff) on tool wear rate (TWR) and surface roughness (SR). The analysis results revealed that the current was the dominant factor affecting the performance measures (62.87% for TWR and 78.82% for SR). The RSM models show very close relation with the experimental and the predicted values with the R2 values of 98.91% and 97.35% for TWR and SR respectively. The Taguchi method can effectively optimize the EDM parameters and confirmation test results showed the minimum error of 6.00% for TWR and 9.67% for SR.

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.

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