Multi-Objective Optimization of Machining Process Parameters in Wire-Cut Electric Discharge Machining of Inconel X750 Alloy by Combinatorial Approach

2019 ◽  
Vol 969 ◽  
pp. 781-786 ◽  
Author(s):  
G. Venkata Ajay Kumar ◽  
M. Shilpa ◽  
Udagave Shital Purander ◽  
G. Madhoo ◽  
V. Asokan
Keyword(s):  
Process Parameters ◽  
Electric Discharge ◽  
Removal Rate ◽  
High Hardness ◽  
Machining Process ◽  
Machining Processes ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Conventional Machining

Difficult-to-cut materials, generally high hardness, strength and toughness, are generally difficult to machine in conventional machining. Also tool wear is high in conventional machining processes. Wire Cut Electric Discharge (WEDM) machining is particularly used for machining complex profiles, demanding very high accuracy. The current work focuses on the optimization of roughness of a surface that is machined using WEDM; the process parameters considered for optimization are pulse-on-time (Pon), pulse-off time (Poff), wire feedrate (WFR) and spark gap voltage (SGV). One of the surface integrity aspect is considered as surface roughness (SR) and other related to machining output considered as material removal rate (MRR) for the output responses. The paper presents, a multi-criteria decision making technique, with Grey Relational Analysis (GRA) integrated with Particle Swarm Optimization (PSO) for optimizing the process parameters. Further, confirmation tests that were conducted also validated the improvement in SR and MRR.

scholarly journals Determination of Multi-performance Characteristics in Electric Discharge Machining of DIN 1.2767 Steel Using Grey Relational Analysis

2021 ◽  
Vol 9 (1) ◽  
pp. 1-7
Author(s):  
Abubaker Y. Fatatit ◽  
Ali Kalyon
Keyword(s):  
Process Parameters ◽  
Electric Discharge ◽  
Removal Rate ◽  
Machining Process ◽  
Gray Relational Analysis ◽  
Machining Processes ◽  
Electric Discharge Machining ◽  
Relational Analysis ◽  
Pulse On Time ◽  
Pulse Off Time

   Electric discharge machining (EDM) is one of the most important unconventional machining processes, which can cut hard materials and complex shapes that are difficult to machine by conventional machining processes easily and with high accuracy. In this study, L18 orthogonal array combined with gray relational analysis (GRA) is implemented to investigate the multiple performances characteristics in EDM of DIN 1.2767 Tool Steel. Machining process parameters selected were discharge current (Ip), pulse-on time (Ton), pulse-off time (Toff), and electrode material (copper alloys [NSS and B2]). The investigated performances characteristics were tool wear rate (TWR) and material removal rate (MRR). Analysis of variance (ANOVA) and Taguchi’s signal-to-noise ratio with the help of Minitab-17 software were used to analysis the effect of the process parameters on TWR and MRR. The experimental results and data analysis reveal that TWR and MRR are more affected by Ip and Ton. The minimum TWR was obtained at parametric combination Ip (6A), Ton (800 μs), and Toff (800 μs) and the maximum MRR attained at Ip (25A), Ton (800 μs), Toff (200 μs), and NSS electrode. After applying GRA, the optimal parametric combination for MRR and TWR was determined as Ip (25A), Ton (800 μs), Toff (200 μs), and NSS electrode. The study also exhibited the occurrence of an interaction between the variables on the responses. In addition, scanning electron microscopy images showed that the metal surface was affected with the increase in Ton and Toff.

scholarly journals Multi-Objective Optimization of Wire Electro Discharge Machining (WEDM) Process Parameters Using Grey-Fuzzy Approach

2018 ◽  
Vol 63 (1) ◽  
pp. 16-25 ◽  
Author(s):  
Partha Protim Das ◽  
Sunny Diyaley ◽  
Shankar Chakraborty ◽  
Ranjan Kumar Ghadai
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Machining Process ◽  
Wire Tension ◽  
Electro Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process ◽  
Fuzzy Logic Technique ◽  
Off Time

Wire electro discharge machining (WEDM) is a versatile non-traditional machining process that is extensively in use to machine the components having intricate profiles and shapes. In WEDM, it is very important to select the optimal process parameters so as to enhance the machine performance. This paper emphasizes the selection of optimal parametric combination of WEDM process while machining on EN31 steel, using grey-fuzzy logic technique. Process parameters such as servo voltage, wire tension, pulse-on-time and pulse-off-time were considered while taking into account several multi-responses such as material removal rate (MRR) and surface roughness (SR). It was found that pulse-on-time of 115 µs, pulse-off-time of 35 µs, servo voltage of 40 V and wire tension of 5 kgf results in a larger value of grey fuzzy reasoning grade (GFRG) which tends to maximize MRR and improve SR. Finally, analysis of variance (ANOVA) is applied to check the influence of each process parameters in the estimation of GFRG.

Experimental Investigation of Sunflower Oil as Dielectric Fluid in Die Sinking Electric Discharge Machining Process

2019 ◽  
Vol 969 ◽  
pp. 715-719
Author(s):  
G. Gowtham Reddy ◽  
Balasubramaniyan Singaravel ◽  
K. Chandra Shekar
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Electric Discharge Machining ◽  
Dielectric Fluids ◽  
Pulse On Time ◽  
Pulse Off Time

Electric Discharge Machining (EDM) is used to machine complex geometries of difficult to cut materials in the area of making dies, mould and tools. Currently, hydrocarbon based dielectric fluids are used in EDM and which plays major role for material removal and it emits harmful emission. In this work, vegetable oil is attempted as dielectric fluid and their performance are studied during processing of AISI P20 steel. The effect of pulse on time (Pon) , pulse off time (Poff), and current (A) on Material Removal Rate (MRR), Tool wear rate (TWR) and surface roughness (SR) are analyzed. The result showed that vegetable oils are given good machining performance than conventional dielectric fluids. These proposed dielectric fluids are biodegradable eco friendly and enhance sustainability in EDM process.

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

2018 ◽  
Vol 28 ◽  
pp. 55-66 ◽  
Author(s):  
Kuldeep Singh ◽  
Khushdeep Goyal ◽  
Deepak Kumar Goyal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Tool Steel ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Pulse On Time ◽  
Pulse Off Time

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

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.

Optimization of Machining Parameters in Rotary EDM Process Using Copper Tungsten Electrode

2015 ◽  
Vol 813-814 ◽  
pp. 368-375
Author(s):  
Suddala Chandramouli ◽  
Kesha Eswaraiah
Keyword(s):  
Process Parameters ◽  
Electric Discharge ◽  
Removal Rate ◽  
Machining Parameters ◽  
Tungsten Electrode ◽  
Electric Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Electrical Discharge Machining is a thermo-electric process and one of the advanced methods of machining. Most publications on the EDM process are directed towards non-rotational tools, but rotation of the tool provides a good flushing in the machining zone. In this study, the optimal setting of the process parameters on Rotary Electric Discharge machining (REDM) was determined. The important process parameters that have been selected are peak current, pulse on time, pulse off time and rotational speed of tool with output response as Material Removal Rate (MRR).Taguchi experimental design (L27 orthogonal array) was used to formulate the experimental layout and experiments were conducted on Hardened stainless steel machined with copper tungsten electrode. ANOVA method was used with the help of MINITAB 17 software to analysis the influence of input process parameters on the MRR using Rotary Electric Discharge Machining. The input parameters were optimized in order to obtain maximum MRR, The results of the present work revealed that proper selection of input parameters will play a significant role on MRR.

Optimization of Process Parameters in EDM Using Taguchi Method with Grey Relational Analysis and Topsis for Ceramic Composites

2016 ◽  
Vol 22 ◽  
pp. 83-93 ◽  
Author(s):  
M. Kalayarasan ◽  
M. Murali
Keyword(s):  
Electric Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Ceramic Composites ◽  
Machining Process ◽  
Electric Discharge Machining ◽  
Relational Analysis ◽  
Grey Relational ◽  
Machining Parameter ◽  
Conventional Machining

Silicon Nitride-Titanium Nitride ceramic composites are newly advanced material having the properties of high hardness, strength, toughness and low density. These kinds of materials are challenging to machine by conventional machining process because it causes severe tool wear due to its properties. Since the materials can be machined by non-conventional machining process like laser cutting and water jet, but these processes are limited. Electric discharge machining shows higher capability for cutting complex shapes with high accuracy. The present work focuses to optimize the process parameter for maximum material removal rate and minimum electrode wear rate. The experimental studies were conducted under varying pulse on time, pulse off time, dielectric pressure and discharge current. Taguchi L9 orthogonal array was used to design the experiments. Grey relational analysis and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) was used to optimize the process parameter and the results were validated by the confirmation tests. Thus the machining parameter for electric discharge machine was optimized to achieve higher material removal rate and lower rate on electrode. The result shows that the proposed technique is being effective to optimize the machining parameter for electric discharge machining process.

Application of Taguchi-Grey Relational Methodology for Multiple Optimal Performance Measures in WEDM Process

2015 ◽  
Vol 766-767 ◽  
pp. 861-866 ◽  
Author(s):  
A. Ramamurthy ◽  
R. Sivaramakrishnan ◽  
S. Venugopal ◽  
T. Muthuramalingam
Keyword(s):  
Performance Measures ◽  
Process Parameters ◽  
Grey Relational Analysis ◽  
Removal Rate ◽  
Optimum Process ◽  
Relational Analysis ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

It is very tedious process to find the optimum multiple performance measures of wire EDM process parameters and role of each parameter to attain the better performance characteristics. Since the WEDM process involves more one than machining characteristics, it is important to carry out the multi-response optimization methodology. In the present study, an attempt has been made to find the optimum process parameters using Taguchi-Grey relational analysis. The machining experiments have been conducted with different levels of input factors such as voltage, peak current, pulse on time, and pulse off time and wire material based on Taguchi L18 orthogonal table. Experimental results have indicated that the multi-response characteristic such material removal rate and surface roughness can be enhanced by 1.2% effectively through grey relational analysis.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Multi-Response Optimization of Wire-EDM Process Parameters of Titanium Alloy Using Taguchi Method and Grey Relational Analysis

2015 ◽  
Vol 772 ◽  
pp. 245-249
Author(s):  
A. Ramamurthy ◽  
R. Sivaramakrishnan ◽  
S. Venugopal ◽  
T. Muthuramalingam
Keyword(s):  
Titanium Alloy ◽  
Process Parameters ◽  
Grey Relational Analysis ◽  
Wire Edm ◽  
Relational Analysis ◽  
Response Optimization ◽  
Grey Relational ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

It is very important and complexity to find the optimum values of wire EDM process parameters and contribution of each parameter to attain the better performance characteristics. In this study, an attempt has been made to optimize those parameters while machining the titanium alloy. Since the process involves more one than one response parameter, it is essential to carry out the multi-response optimization methodology .The experiments have been conducted with different levels of input factors such as pulse on time,pulse off time and wire tension based on Taguchi L9 orthogonal table.Wire EDM optimal process parameter has been identified using grey relational analysis and significant parameter has been determined by analysis of variance. Experimental results have indicated that the multi-response characteristic such as material removal rate and surface roughness can be improved effectively through grey relational analysis.

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