Application of Machine Learning Techniques for Multi Objective Optimization of Response Variables in Wire Cut Electro Discharge Machining Operation

2019 ◽  
Vol 969 ◽  
pp. 800-806
Author(s):  
Sidharth Kumar Shukla ◽  
Amrita Priyadarshini
Keyword(s):  
Machine Learning ◽  
Surface Roughness ◽  
Gradient Descent ◽  
Descent Method ◽  
Kerf Width ◽  
Gradient Descent Method ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire Cut Electrical Discharge Machining (WEDM) is a non-conventional thermal machining process which is capable of accurately machine alloys having high hardness or part having complex shapes that are very difficult to be machined by the conventional machining processes. The WEDM finds applications in automobiles, aero–space, medical instruments, tool and die industries, etc. The input parameters considered for WEDM are pulse on time, pulse off time, flushing pressure, servo voltage, wire feed rate and wire tension. Performance of WEDM is mainly assessed by output variables such as, material removal rate (MRR), kerf width (Kw) and surface roughness (Ra) of the work piece being machined. Looking at the need of a suitable optimization model, the present work explores the feasibility of machine learning concepts to predict optimum surface roughness and kerf width simultaneously by making use of experimental data available in the literature for machining of Hastelloy C– 276 using WEDM. In most of the literatures, single objective optimization has been carried out for predicting optimum cutting parameters for WEDM. Hence, the present work presents a methodology that makes use of a machine learning algorithm namely, gradient descent method as an optimization technique to optimize both surface roughness and kerf width simultaneously (multi objective optimization) and compare the results with the existing literatures. It was observed that the input parameters such as pulse on time, pulse off time, and peak current have significant effect on both surface roughness and kerf width. The gradient descent method was successfully used for predicting the optimum values of response variables.

scholarly journals Findings of performance evaluation of EDM for different materials of electrodes and work pieces- a review

2018 ◽  
Vol 7 (4.5) ◽  
pp. 542
Author(s):  
Harshalkumar R. Mundane ◽  
Dr. A. V. Kale ◽  
Dr. J. P. Giri
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Performance Measure ◽  
Machining Process ◽  
Machining Parameters ◽  
Spark Erosion ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

EDM (Spark erosion) is non-conventional machining process which uses as removing unwanted material by electrical spark erosion. EDM Machining parameters affecting to the performance and the industries goal is to produce high quality of product with less time consuming and cost. To achieve these goals, optimizing the machining parameters such as pulse on time, pulse off time, cutting speed, depth of cut, duty cycle, arc gap, voltage etc. The performance measure of EDM is calculated on the basis of Material Remove Rate(MRR), Tool Wear Rate(TWR), and Surface Roughness(SR).The main objective of present work is to investigate of the influence of input EDM (Electro Discharge Machining) parameters on machining characteristics like surface roughness and the effects of various EDM process parameters such as pulse on time, pulse off time, servo voltage, peak current, dielectric flow rate, on different process response parameters such as material removal rate (MRR), surface roughness (Ra), Kerf (width of Cut), tool wear ratio(TWR)and surface integrity factors. In this paper few selected research paper related to Die-sinker EDM with effect of MRR, TWR, surface roughness (SR) and work piece material have been discussed.   

A Comparison of the Effects of Wire Electrical Discharge Machining Parameters on the Processing of Traditionally Manufactured and Additively Manufactured 316L Stainless Steel Specimens

2018 ◽  
Author(s):  
Gregory Bicknell ◽  
Guha Manogharan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
316L Stainless Steel ◽  
Machining Parameters ◽  
Wire Edm ◽  
Machining Time ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire electric discharge machining (EDM) is a non-traditional machining method that has the ability to machine hard, conductive materials, with no force and high precision. This technology is used in industries, like the aerospace industry, to create precision parts used in high stress applications. Wire EDM is also commonly used in additive manufacturing (AM) applications to remove printed parts from the base-plates onto which they are printed. Numerous studies show the effects of EDM parameters, like pulse-on time, pulse-off time, and cutting voltage, on the processing of traditionally fabricated metal parts. However, very few studies identify how the parameters of wire EDM affect the processing of AM parts. This paper studies the effect of wire EDM pulse-on time, pulse-off time, and cutting voltage on the machining time, surface roughness, and hardness of additively manufactured 316L stainless steel cylinders. The effects of these wire EDM parameters are then tested on the machining time, surface roughness, and hardness of wrought 316L stainless steel cylinders. It was found that machining time of AM samples was statistically significantly lower than wrought samples and also had better surface finish and lower surface hardness.

scholarly journals Parametric Study of Machining on EN31 and EN19 Alloy Steels in WEDM to Analyze the Effect on Surface Roughness

2018 ◽  
Vol 7 (2) ◽  
pp. 36-42
Author(s):  
Ramandeep Singh ◽  
Ashok Kumar
Keyword(s):  
Surface Roughness ◽  
Input Parameter ◽  
Hard Materials ◽  
Current Voltage ◽  
Alloy Steels ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

Wire EDM can machine hard materials as well as alloys. Thus this study aims to analyze the effect of process parameters in WEDM on EN31 and EN19 alloy steels. The parameters selected for the optimization were Work material, Pulse on Time, Pulse off Time, Current, Voltage and Wire Feed for improvement in surface roughness. Taguchi L18 Orthogonal array was used for the best combination of experiment. The output responses were analyzed by ANOVA (Analysis of variance). The ANOVA result indicated that there is a significant effect on improvement in surface roughness when machining with all these six input parameter and coated wire. According to the present investigation, voltage was found to be the most significant factor followed by Ton and current, which affect the improvement in surface roughness.

Investigation of the Effect of Process Parameters on Surface Roughness in Wire EDM of Titanium Alloy

2012 ◽  
Vol 472-475 ◽  
pp. 78-81 ◽  
Author(s):  
Mohinder Pal Garg ◽  
Ajai Jain ◽  
Gian Bhushan
Keyword(s):  
Surface Roughness ◽  
Water Pressure ◽  
Peak Voltage ◽  
Peak Current ◽  
Wire Breakage ◽  
Pulse Peak ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

This paper investigates the Wire Electric Discharge Machining of Titanium alloy 6-2-4-2.Eight process parameters namely pulse-on time, pulse-off time, peak current, spark gap set voltage, wire feed, wire tension, water pressure, pulse peak voltage and servo feed are varied to study their effect on surface roughness and wire breakage. The experiments are conducted using one-factor-at-a-time approach. Moreover, a few random experiments are also carried to study the phenomenon of wire breakage precisely. The study revealed that surface roughness is directly affected by the pulse-on time, pulse-off time, peak- current, spark gap set voltage and wire tension. Wire feed, Water pressure and pulse peak voltage have negligible effect on the surface roughness. Moreover, wire breakage is predominantly dictated by all the parameters except peak current and pulse peak voltage. An optimum range of input parameters has been bracketed as the final outcome for cutting in terms of surface roughness and to minimize the wire breakage frequency.

A Study on Surface Roughness and Cutting Width for Circular Contour Machining of Stir Cast AA6063/SiC Composites in WEDM

2017 ◽  
Vol 13 (10) ◽  
pp. 6524-6530
Author(s):  
I. Balasubramanian
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Stir Casting ◽  
Circular Contour ◽  
Sic Composites ◽  
Contour Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Time Pulse

Wire electrical discharge machining is used in machining electric conductive materials with intricate shapes and profiles. This paper presents an experimental investigation on the influence of cutting conditions of WEDM on surface roughness and cutting width of machining of AA6063/SiC composites. Here a semi cylindrical piece is removed from a rectangular plate of AA6063/SiC composites plate fabricated with reinforcing SiC in 0%, 5%, 10% and 15% weight fractions through stir casting. The effect of WEDM parameters such as pulse on time, pulse off time and peak current on surface roughness and cutting width on different composition of AA6063/SiC were analyzed for circular contour machining. The experimental results show that increase in percentage of SiC has high influence in mechanical behavior of AA6063/SiC composites and the effect of pulse on time is very significant in reducing the surface roughness and pulse off time plays an important role in producing minimum cutting width.  

Investigation of Surface Roughness for Inconel 718 in Blind Hole Drilling with Rotary Tool Electrode

2019 ◽  
Vol 18 (03) ◽  
pp. 379-394
Author(s):  
Rakesh Kumar ◽  
Anand Pandey ◽  
Pooja Sharma
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Work Piece ◽  
Tool Electrode ◽  
Tool Diameter ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Tool Rotation ◽  
Off Time ◽  
Time Pulse

The research investigation reported on the effect of machining parameters on surface roughness (Ra) in electric discharge drilling of Inconel 718. Machining was done by using a copper tool electrode. Machining was conducted by considering different process parameters viz. tool diameter, discharge current, pulse on time, pulse off time, tool rotation and depth of hole. Optical surface profiler was used to measure surface roughness of drilled hole in work-piece. Design of experiment was created by Taguchi method based L18 orthogonal array. For minimum surface roughness, optimum parameters were found using Analysis of variance (ANOVA). Based on analysis, it is found that pulse off time, pulse on time and tool rotation are the most significant parameters that affect the surface roughness. Tool diameter is the less significant parameter that affects the surface roughness. Regression analysis was used to predict a value for minimum surface roughness. The scanning electron microscope (SEM) images were used to identify the microstructure of the drilled hole in Inconel 718 work-piece. Interaction plots and residual plot have been plotted for surface roughness to identify the interaction between parameters and residual errors, respectively.

Experimental Evaluation on Corner Accuracy in WEDM for Aluminium 6061 Alloy

2021 ◽  
pp. 96-113
Author(s):  
Debal Pramanik ◽  
Dipankar Bose
Keyword(s):  
Electrical Discharge ◽  
Thermal Process ◽  
Electrical Discharge Machining ◽  
Sharp Corner ◽  
Proposed Model ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time ◽  
Wire Feed ◽  
Time Pulse

An important electro-thermal process known as wire electrical discharge machining (WEDM) is applied for machining of conductive materials to generate most precisely. All cutting inaccuracies of WEDM arise out of the major cause of wire bending. At the time of cutting a sharp corner or cut profile, bending of the wire leads to a geometrical error on the workpiece. Though this type of error may be of a few hundred microns, it is not suitable for micro applications. In this research study, an experimental investigation based on response surface methodology (RSM) has been done on wire EDM of Aluminium 6061 t6 alloy. This chapter studies the outcome of input process variables (i.e., wire feed rate, pulse on time, pulse off time, and gap voltage) on machining output responses (i.e., corner inaccuracy) extensively. Experimental validation of the proposed model shows that corner inaccuracy value may be reduced by modification of input parameters.

Optimization of Machining Time and Surface Quality of AISI D2 Tool Steel in WEDM Using Taguchi Methodology and Desirability Analysis

2020 ◽  
Vol 977 ◽  
pp. 27-33
Author(s):  
Carmita Camposeco-Negrete ◽  
Juan de Dios Calderón-Nájera
Keyword(s):  
Surface Roughness ◽  
Tool Steel ◽  
Cutting Parameters ◽  
Machining Time ◽  
Aisi D2 ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Aisi D2 Tool Steel ◽  
Off Time

One of the non-conventional machining processes widely used in the industry is the wire electrical discharge machining (WEDM). This process has many advantages, like the great precision and quality that can be achieved. As well as other manufacturing operations, the success of the process relies on a correct selection of the cutting parameters. The present paper outlines an experimental study to optimize the machining time and the surface roughness in WEDM of AISI D2 tool steel during roughing machining. The Taguchi methodology is used to evaluate the effects and contributions of the pulse-on time, pulse-off time, servo voltage, and wire speed, on the response variables. The desirability method is employed to define a set of cutting parameters that allows reducing both machining time and surface roughness at the same time. The pulse-on time is the most significant factor for reducing the machining time, followed by the servo voltage, the pulse-off time and the wire speed. For surface roughness, the pulse-off time is the factor with the greatest influence over the response variable. The results obtained show that the machining time is reduced by 4.65%, and the surface roughness is diminished by 4.60% when compared with the initial values that are commonly used in the machining of AISI D2 tool steel. Therefore, greater production rates can be achieved without compromising the quality of the machined parts.

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.

Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of Ti-6Al-4V Using Zinc Coated Brass Wire

2014 ◽  
Vol 592-594 ◽  
pp. 416-420 ◽  
Author(s):  
Singaravelu D. Lenin ◽  
A. Uthirapathi ◽  
Ramana Reddy P.S. Venkata ◽  
Muthukannan Durai Selvam
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Dielectric Fluid ◽  
Wire Electrical Discharge Machining ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Brass Wire

The present paper describes the influence of pulse-on-time on performance features such as Metal Removal Rate (MRR), Kerf width, Surface Roughness (SR) on cutting Titanium alloy (Ti-6Al-4V) in wire electrical discharge machining (WEDM) using zinc coated brass wire. The deionised water is used as dielectric fluid. The process parameters such as wire tension, wire speed, flushing pressure, discharge current, sparking voltage and pulse off time have kept constant at appropriate values throughout the experiment and the pulse on time is varied at nine different intervals. It was found that pulse-on-time is the most significant factor which greatly influences MRR, kerf width, and SR. It was also observed that taper at the end of cutting zone which is unavoidable occurrence for the machined part. This is due to the erosion of wire material. The surface roughness increases with increase in pulse on time also with higher rate of MRR.

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