scholarly journals Multi-Response Optimization of Electrical Discharge Machining Using the Desirability Function

Micromachines ◽  
2019 ◽  
Vol 10 (1) ◽  
pp. 72 ◽  
Author(s):  
Rafał Świercz ◽  
Dorota Oniszczuk-Świercz ◽  
Tomasz Chmielewski
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Desirability Function ◽  
Statistical Significance ◽  
Time Interval ◽  
Machining Parameters ◽  
Response Optimization

Electrical discharge machining (EDM) is a modern technology that is widely used in the production of difficult to cut conductive materials. The basic problem of EDM is the stochastic nature of electrical discharges. The optimal selection of machining parameters to achieve micron surface roughness and the recast layer with the maximal possible value of the material removal rate (MRR) is quite challenging. In this paper, we performed an analytical and experimental investigation of the influence of the EDM parameters: Surface integrity and MRR. Response surface methodology (RSM) was used to build empirical models on the influence of the discharge current I, pulse time ton, and the time interval toff, on the surface roughness (Sa), the thickness of the white layer (WL), and the MRR, during the machining of tool steel 55NiCrMoV7. The surface and subsurface integrity were evaluated using an optical microscope and a scanning profilometer. Analysis of variance (ANOVA) was used to establish the statistical significance parameters. The calculated contribution indicated that the discharge current had the most influence (over the 50%) on the Sa, WL, and MRR, followed by the discharge time. The multi-response optimization was carried out using the desirability function for the three cases of EDM: Finishing, semi-finishing, and roughing. The confirmation test showed that maximal errors between the predicted and the obtained values did not exceed 6%.

scholarly journals Analysis, predictive modelling and multi-response optimization in electrical discharge machining of Al-22%SiC metal matrix composite for minimization of surface roughness and hole overcut

2020 ◽  
Vol 7 ◽  
pp. 20 ◽  
Author(s):  
Subhashree Naik ◽  
Sudhansu Ranjan Das ◽  
Debabrata Dhupal
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Discharge Current ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Machining Parameters ◽  
Response Optimization ◽  
Pulse On Time

Due to the widespread engineering applications of metal matrix composites especially in automotive, aerospace, military, and electricity industries; the achievement of desired shape and contour of the machined end product with intricate geometry and dimensions that are very challenging task. This experimental investigation deals with electrical discharge machining of newly engineered metal matrix composite of aluminum reinforced with 22 wt.% of silicon carbide particles (Al-22%SiC MMC) using a brass electrode to analyze the machined part quality concerning surface roughness and overcut. Forty-six sets of experimental trials are conducted by considering five machining parameters (discharge current, gap voltage, pulse-on-time, pulse-off-time and flushing pressure) based on Box-Behnken's design of experiments (BBDOEs). This article demonstrates the methodology for predictive modeling and multi-response optimization of machining accuracy and surface quality to enhance the hole quality in Al-SiC based MMC, employing response surface methodology (RSM) and desirability function approach (DFA). Finally, a novel approach has been proposed for economic analysis which estimated the total machining cost per part of rupees 211.08 during EDM of Al-SiC MMC under optimum machining conditions. Thereafter, under the influence of discharge current several observations are performed on machined surface morphology and hole characteristics by scanning electron microscope to establish the process. The result shows that discharge current has the significant contribution (38.16% for Ra, 37.12% in case of OC) in degradation of surface finish as well as the dimensional deviation of hole diameter, especially overcut. The machining data generated for the Al-SiC MMC will be useful for the industry.

A Comparative Study of Machining Parameters on Die-Sinking Electrical Discharge Machining (EDM) using Copper and Aluminium Electrodes on Hard Steels

2016 ◽  
Vol 3 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Ashwani Kharola
Keyword(s):  
Surface Roughness ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Die Steel ◽  
The Relationship

This paper considers effect of variation in value of Discharge current on different process parameters of Die Sinking EDM. The parameters considered were Material removal rate (MRR), Tool removal rate (TRR), Surface roughness (Ra) and Time (for machining required depth of cut). A total of 32 experiments were conducted on four different hard steels i.e. Die steel D3, En-8, En-19 and Stainless steel (SS-AISI-440C). The Copper and Aluminium electrodes brazed with mild steel were used for machining. The four different values of current i.e. 6A, 9A, 12A and 15A were considered for the study. The experimental results shows the relationship between MRR, TRR, Ra and Time with variation in magnitude of discharge current. This study also illustrates the relationship among different process parameter considered in the study. The results are shown with the help of graphs and tables.

Experimental Investigation of Machining Parameters on Surface Roughness in Dry and Wet Wire-Electrical Discharge Machining

2011 ◽  
Vol 264-265 ◽  
pp. 831-836 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Zakaria Mohd Zain
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Local Heating ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Good Surface ◽  
Good Surface Finish ◽  
Wedm Process

Wire electrical discharge machining (WEDM) is a thermal process in which the workpiece and the wire (tool) experience an intense local heating in the discharge channel. The high power density results in the erosion of a part of the material from both electrodes by local melting and vaporization. Whilst good surface finish and high material removal rate of the workpiece is a major requirement, the effect of EDM machining factors on these requirements cannot be overlooked. This study investigate the effect of two different machining methods of dry and wet WEDM process as well as the effect of on-time and voltage on the surface roughness of the workpiece. The machining factors used for this study are the pulse current, on-time and voltage. The results of the effect of the two machining methods on the responses are investigated and reported in this paper.

Modeling and Multi-Response Optimization on WEDM Ti6Al4V

2014 ◽  
Vol 510 ◽  
pp. 123-129 ◽  
Author(s):  
J.B. Saedon ◽  
Norkamal Jaafar ◽  
Roseleena Jaafar ◽  
Nor Hayati Saad ◽  
Mohd Shahir Kasim
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Desirability Function ◽  
Cutting Speed ◽  
Percentage Error ◽  
Machining Parameters ◽  
Thermo Electric ◽  
Average Percentage ◽  
Response Optimization ◽  
Average Percentage Error

Wire electrical discharge machining (WEDM) is a material removal process of electrically conductive materials by the thermo-electric source of energy which is extensively used in machining of materials for a highly precision productivity. This work presents the machining of titanium alloy (TI-6AL-4V) using WEDM with a brass wire diameter of 0.25mm.The objective of this work is to study the influence of three machining parameters, namely peak current (IP), feed rate (FC) and wire tension (WT) to cutting speed and surface roughness. Response Surface Methodology was used to develop second order model in order to predict cutting rate and surface roughness responses. The results showed that the average percentage error between the predicted and experimental value for both models was less than 2%.Furthermore, the developed models were used for multiple-response optimization by desirability function approach to determine the optimum machining parameters. These optimized machining parameters are validated experimentally, and it is observed that the response values are in good agreement with the predicted values.

scholarly journals Investigation on Material Removal Rate and Surface Finish in Electrical Discharge Machining of AA 6061-B4C Composite Material

2021 ◽  
Vol 23 (12) ◽  
pp. 224-235
Author(s):  
N. Ethiraj ◽  
◽  
T. Sivabalan ◽  
Saibal Chatterjee ◽  
Seeramsetti Mahesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse On Time

One of the non-conventional techniques of metal removal manufacturing processes is electrical discharge machining (EDM). The objective of this paper is to prepare a composite material consisting of a matrix of Aluminium AA 6061 alloy and Boron carbide (B4C) as reinforcement and investigate the output responses, the material removal rate, the quality of the surface formed and overcut during EDM process. The process parameters discharge current, Pulse on time and Duty cycle along with the weight % of B4C are considered for investigation to investigate the output responses such as material removal rate, surface roughness and overcut. From the experimental results, it is observed that the weight % of reinforcement has more influence on the material removal rate. The parameters discharge current and pulse-on-time plays an important role in reducing the surface roughness and overcut. Microstructural study helps in understanding the effect of process parameters on the output responses.

Electro Discharge Machining of WC/Ni Mixed Ceramic

2015 ◽  
Vol 813-814 ◽  
pp. 309-316
Author(s):  
Vasudevan Chandrasekaran ◽  
D. Kanagarajan ◽  
R. Karthikeyan
Keyword(s):  
Mathematical Models ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Significance ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Mixed Ceramic

Proper selection of manufacturing conditions is one of the most important aspects in the die sinking Electrical Discharge Machining (EDM) process, as these conditions determine important characteristics such as Material Removal Rate and Surface Roughness.In this work, mathematical models have been developed for relating the Material Removal Rate (MRR) and Surface Roughness (Ra), to machining parameters like tool rotational speed (S), discharge current (C), pulse-on time (T) and flushing pressure (P). The experiment plan adopts the centered central composite design unblocked (CCD). The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). This study highlights that the proposed mathematical models have proven to fit and predict values of performance characteristics close to those readings recorded experimentally with a 95% confidence interval. Results show that are the two significant factors affecting MRR (discharge current and flushing pressure). The discharge current, flushing pressure and electrode rotation have statistical significance on the Ra.

Parametric Optimization of Wire Cut Electrical Discharge Machining on Al-9% PAC Composites using Desirability Approach

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
G. Ramanan ◽  
R. Elangovan
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

In aerospace and automobile industries manufacturing complex structures using un-conventional machining is increased due to their precision and accuracy. This research investigates the influence of input parameters such as discharge current, pulse on time, pulse off time and servo speed rate of wire cut electrical discharge machining (WEDM) on material removal rate and surface roughness using Box Behnken design supported with response surface methodology. Aluminium alloy 7075 reinforced with 9 % wt. of activated carbon composite is used to carry out the machining process. Most influencing parameters are subjected as the conductive and non-conductive parameters in WEDM process. To find out the significant influence of each factor, analysis of variance was performed. The mathematical model is established using desirability technique and then the optimal machining parameters are determined. The best achieved WEDM performances - material removal rate and surface roughness are 10.46 mm3/min and 3.32μm respectively, by using optimum machining conditions - discharge current 2000mA, pulse on time 8.9µs, pulse off time 25µs and servo speed rate 150rpm at 0.8597 desirability value.

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