Evaluation of Optimal Parameters for Machining Aluminium Alloy Al6061 in Wire EDM

2014 ◽  
Vol 592-594 ◽  
pp. 282-288
Author(s):  
T. Bharathy ◽  
K. Thiruppathi ◽  
S. Raghuraman
Keyword(s):  
Aluminium Alloy ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Objective Measure ◽  
Wire Edm ◽  
Machined Surface ◽  
Optimization Of Process Parameters ◽  
Grey Relational Grade ◽  
Grey Relational

This paper discuss on the optimization of process parameters for the machining of Al6061 aluminium alloy in Wire Electrical Discharge Machining (WEDM). Al6061 has a significant use in various domains like aerospace, ordnance, and automotive sectors. Wire EDM is used in the fields of Dies, Moulds Precision Manufacturing and contour cutting. The experiments have been conducted by varying four process parameters such as Peak current, Ton, Toffand Servo feed in three different levels. The important output measurable parameters like material removal rate (MRR), Surface roughness (Ra) value of the machined surface for each experimental runs has been measured. Taguchi’s L9(34) Orthogonal Array was employed to carry on the experiments, that agree with arbitrarily opted distinct combinations of the mentioned process parameter. All experiments have been conducted using Electronica Sprintcut WEDM. Grey relational analysis was employed to change over the multi-objective measure into a tantamount individual objective function. Taguchi technique was used to optimize the overall grey relational grade. Verification experiments were done to validate the optimal results.

Optimization of Process Parameters Using Soft Computing Techniques

2017 ◽  
pp. 177-220
Author(s):  
Supriyo Roy ◽  
Kaushik Kumar ◽  
J. Paulo Davim
Keyword(s):  
Soft Computing ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Principal Component ◽  
Optimization Of Process Parameters ◽  
Hard Metals ◽  
Optimal Values ◽  
Grey Relational ◽  
Conventional Machining

Machining of hard metals and alloys using Conventional machining involves increased demand of time, energy and cost. It causes tool wear resulting in loss of quality of the product. Non-conventional machining, on the other hand produces product with minimum time and at desired level of accuracy. In the present study, EN19 steel was machined using CNC Wire Electrical discharge machining with pre-defined process parameters. Material Removal Rate and Surface roughness were considered as responses for this study. The present optimization problem is single and as well as multi-response. Considering the complexities of this present problem, experimental data were generated and the results were analyzed by using Taguchi, Grey Relational Analysis and Weighted Principal Component Analysis under soft computing approach. Responses variances with the variation of process parameters were thoroughly studied and analyzed; also ‘best optimal values' were identified. The result shows an improvement in responses from mean to optimal values of process parameters.

Optimization and surface modification in electrical discharge machining of AA 6061/SiCp composite using Cu–W electrode

2015 ◽  
Vol 231 (3) ◽  
pp. 332-348 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Material Transfer ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time ◽  
Pulse Off Time

This paper presents the experimental investigation on the electro-discharge machining of aluminum alloy 6061 reinforced with SiC particles using sintered Cu–W electrode. Experiments have been designed as per central composite rotatable design, using response surface methodology. Machining characteristics such as material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated under the influence of four electrical process parameters; namely peak current, pulse on time, pulse off time, and gap voltage. The process parameters have been optimized to obtain optimal combination of MRR, EWR, and SR. Further, the influence of sintered Cu–W electrode on surface characteristics has been analyzed with scanning electron microscopy, energy dispersive spectroscopy, and Vicker microhardness tests. The results revealed that all the process parameters significantly affect MRR, EWR, and SR. The machined surface properties are modified as a result of material transfer from the electrode. The recast layer thickness is increased at higher setting of electrical parameters. The hardness across the machined surface is also increased by the use of sintered Cu–W electrode.

scholarly journals Multi Performance Optimizationof Shoulder Milling Process Parameters of AA6063 T6 Aluminium Alloy by Taguchi Based GRA

2019 ◽  
Vol 8 (10S) ◽  
pp. 420-425
Keyword(s):  
Process Parameters ◽  
Grey Relational Analysis ◽  
Removal Rate ◽  
Analysis Data ◽  
Milling Process ◽  
Depth Of Cut ◽  
Analysis Method ◽  
Relational Analysis ◽  
Grey Relational Grade ◽  
Grey Relational

In this paper, a grey relational analysis method based on Taguchi is proposed to improve the multi-performance characteristics of VMC shoulder milling process parameters in the processing of AA6063 T6. Taking into account four process parameters such as coolant, depth of cut,speed and feed, there are three level of each process parameter in addition to two levels of coolant. 18 experiments were used by L18 orthogonal array using the taguchi method. Multi-performance features like surface roughness and material removal rate are used. Grey Relational Analysis method is used to obtain the Grey Relational Grade, and the multiperformance characteristics of the process are pointed out. Then, the Taguchi response table method and ANOVA are used to analysis data. In order to ensure the validity of the test results, a confirmation test was conducted. The study also shows that this method can effectively improve the multi-function characteristics of shoulder milling process.In his work microstructure and mechanical properties of AA6063 T6before and after shoulder milling have been investigated.

scholarly journals A Study on Optimization of Process Parameters in Machining of Bronze using Wire-EDM

2021 ◽  
pp. 484-493
Author(s):  
Gajanan Kamble ◽  
Dr. N. Lakshamanaswamy ◽  
Gangadhara H S ◽  
Sharon Markus ◽  
N. Rajath
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Parameters ◽  
Wire Edm ◽  
Pulse On Time ◽  
Pulse Off Time

Wire cut electrical discharge machining (WEDM) is a hybrid manufacturing technology which enables machining of all engineering materials. This research article deals with investigation on Optimization of the Process Parameters of the wire cut EDM of Bronze material of dimension (80*80*40) in mm. Material removal rate, Surface roughness and Kerf width were studied against the process parameters such as Pulse on time(TON), Pulse off time (TOFF) and Current(IP). The machining parameters for wire EDM were optimized for achieving the combined objectives. As there are three input parameters 27 experiments is carried out and full factorial is used. Optimized parameters were found using (ANOVA) and the error percentage can be validated and parameter contribution for the Material removal rate (MRR) and Surface roughness were found.

Optimization of Process Parameters for Silicon Carbide Powder Mixed EDM

2019 ◽  
pp. 55-81
Author(s):  
Sasmeeta Tripathy ◽  
Deba Kumar Tripathy
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Base Material ◽  
Carbide Powder ◽  
Electrode Wear ◽  
Powder Concentration ◽  
Optimization Of Process Parameters ◽  
Recast Layer Thickness ◽  
Grey Relational ◽  
Pulse On Time

The present chapter deals with the investigations on the effect of process parameters like powder concentration (Cp), peak current (Ip), pulse-on-time (Ton), duty cycle (DC), and gap voltage (Vg) on output responses like material removal rate (MRR), tool wear rate (TWR), electrode wear ratio (EWR), surface roughness (SR), recast layer thickness (RLT), and micro-hardness (HVN) for PMEDM of H-11 hot work tool steel. Multi-objective optimization using grey relational analysis (GRA) has been implemented to identify the optimum set of input parameters to achieve maximum MRR and HVN with minimum TWR, EWR, SR, and RLT at the same time. Predicted results on verification with confirmation tests improve the preference values by 0.09468 with GRA. The recommended settings of process parameters is found to be Cp=6g/l, Ip=3Amp, Ton=100µs, DC=70%, and Vg=30V from GRA. The microstructures were examined with scanning electron microscope (SEM) to find the presence of surface deformities and identify alterations on the surface in comparison to the base material.

Parametric Influence and Optimization of Wire EDM on Oil Hardened Non Shrinking Steel

2011 ◽  
Author(s):  
Nixon Kuruvila ◽  
H. V. Ravindra
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Dimensional Accuracy ◽  
Optimum Process ◽  
Machining Parameters ◽  
Wire Edm ◽  
Flushing Rate ◽  
Optimization Of Process Parameters ◽  
The Matrix ◽  
Taguchi’S Technique

Wire-cut Electro Discharge Machining (WEDM) is a special form of conventional EDM process in which electrode is a continuously moving conductive wire. The present study aims at determining parametric influence and optimum process parameters of Wire-EDM using Taguchi’s Technique and Genetic algorithm. The variation of the performance parameters with machining parameters was mathematically modeled by Regression analysis method. The objective functions are Dimensional Accuracy (DA) and Volumetric Material Removal Rate (VMRR). Experiments were designed as per Taguchi’s L16 Orthogonal Array (OA) where in Pulse-on duration, Current, Pulse-off duration, Bed-speed and Flushing rate have been considered as the important input parameters. The matrix experiments were conducted for the material Oil Hardened Non Shrinking Steel (OHNS) having the thickness of 40 mm. The results of the study reveals that among the machining parameters it is preferable to go in for smaller pulse-off duration for achieving over all good performance. Regarding MRR, OHNS is to be eroded with medium pulse-off duration and higher flush rate. Finally, the validation exercise performed with the optimum levels of the process parameters. The results confirm the efficiency of the approach employed for optimization of process parameters in this study.

Sign in / Sign up

Export Citation Format

Share Document