scholarly journals Intelligent optimization of wire-EDM parameters for surface roughness and material removal rate while machining WC-Co composite

2021 ◽  
Vol 49 (3) ◽  
pp. 756-763
Author(s):  
Kapil Gupta

This work presents the wire-EDM of WC-Co composite and optimization of process parameters using an integrated technique of response surface methodology (RSM), Vise Kriterijumska Optimizacija Kompromisno Resenje (VIKOR) and artificial bee colony (ABC) algorithm to obtain the best set of machinability indicators. Wire feed (WF), servo voltage (SV), pulse off-time (Pon) and pulse on-time (Poff) are the variable process parameters, whereas root mean square roughness (Rq), average surface roughness (Ra) and material removal rate (MRR) are the machinability indicators considered in the present work. A total of twenty nine experiments have been conducted based on Box Behnken design (BBD) technique of response surface methodology. VIKOR has been used for normalization of responses and followed by solving empirical models using ABC algorithm to obtain optimized process parameters setting. WF-12 m/min, SV-65V, Pon-116 µs, Poff-20 µs are the optimum wire-EDM parameters obtained by intelligent RSM-VIKOR-ABC technique that produced best values of Ra-4.51 µm, Rq-5.64 µm, MRR-0.061 mm3 /min simultaneously. The validation test confirmed an improvement up to 15% in the response characteristics which proved the effectiveness of this novel hybrid technique for optimization. The optimum parameter setting is for ready industrial reference to attain best surface quality and process productivity for WC-Co composite machining by wire-EDM.

2014 ◽  
Vol 541-542 ◽  
pp. 354-358 ◽  
Author(s):  
C. Nandakumar ◽  
B. Mohan

This research deals with the multi-response optimization of CNC WEDM process parameters for machining titanium alloy Ti 6AI-4V using Response Surface Methodology (RSM) to achieve higher Material Removal Rate (MRR) and lower surface roughness (Ra). The process parameters of CNC WEDM namely pulse-on time (TON), pulse-off time (TOFF) and wire feed rate (WF) were optimized to study the responses in terms of material removal rate and surface roughness. The surface plot and the contour plots were generated between the process parameters and the responses using MINITAB software. The results show that the Response surface methodology (RSM) is a powerful tool for providing experimental diagrams and statistical-mathematical models to perform the experiments appropriately and economically.


2007 ◽  
Vol 364-366 ◽  
pp. 733-738
Author(s):  
Feng Jiao ◽  
Bo Zhao ◽  
Chuan Shao Liu ◽  
Xun Sheng Zhu

Aimed at the precision machining characteristics of nano ZTA engineering ceramics external cylindrical components, ultrasonic aided lapping experiments were carried out adopting inhouse developed ultrasonic external cylindrical lapping device with solid abrasive material. To obtain minimum surface roughness with constraint of the material removal rate, response surface methodology (RSM) was adopted to analyze the experimental data, and suitable experiment design was chosen to fit the response surface in this research. Second-order surface response models of surface roughness and material removal rate were developed respectively, and the influence laws of lapping parameters on surface roughness and material removal rate were clarified according to the built models. Finally, parameters optimization of the ultrasonic external cylindrical lapping process for nano ZTA engineering ceramics was realized using surface response methodology.


2014 ◽  
Vol 592-594 ◽  
pp. 831-835 ◽  
Author(s):  
Vikram Singh ◽  
Sharad Kumar Pradhan

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.


Author(s):  
Gajanan Kamble ◽  
Dr. N. Lakshamanaswamy ◽  
Gangadhara H S ◽  
Sharon Markus ◽  
N. Rajath

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.


2019 ◽  
Vol 1 (01) ◽  
pp. 40
Author(s):  
Yon Haryono

Performansi yang diharapkan dari proses pemesinan Wire-EDM adalah laju pembuangan material (material removal rate) yang tinggi dan kualitas permukaan (surface integrity) yang baik. Akan tetapi kondisi tersebut  tidak mudah untuk dilakukan karena banyaknya variabel yang mempengaruhi kinerja proses pemesinan Wire-EDM.             Salah satu upaya untuk mencari solusi dari problem diatas adalah dengan menentukan hubungan antara kinerja proses dengan variabel proses, kemudian dicari kombinasi level variabel proses yang dapat memberikan performansi proses optimum. Penelitian ini dilakukan untuk mengembangkan model dari proses Wire-EDM dengan mengadopsi Response Surface Methodology (RSM). Durasi pulsa, kuat arus, tegangan mekanik  kawat dan kecepatan kawat dipilih sebagai variabel proses, sedangkan laju pembuangan material/material removal rate  (MRR) dan kekasaran permukaan sebagai respon. Proses optimasi dual response dilakukan dengan bantuan paket program aplikasi Quantitative System untuk kasus inequality constraint.             Hasil yang didapatkan menunjukakan bahwa variabel proses yang dipilih memberikan pengaruh yang signifikan terhadap respon. Laju pembuangan material dan kekasaran permukaan mancapai kondisi optimal secara bersamaan pada kombinasi durasi pulsa 3.83  ms,  kuat arus 2,74 amper, tegangan mekanik kawat 998,93 gr/mm2, dan kecepatan kawat 1419,29 cm/min. Pada seting variabel proses seperti tersebut diatas dihasilkan MRR sebesar 11,48 mm3/min dan kekasaran permukaan 1,86 mm.


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