Optimizing Material Removal Rate Using Artificial Neural Network for Micro-EDM

Machining can be classified into conventional and unconventional processes. Unconventional Machining Process attracts researchers as it has many processes whose physics is still not that clear and they are highly in market-demand. To predict and understand the physics behind these processes soft computing is being used. Soft computing is an approach of computing which is based on the way a human brain learns and get trained to deal with different situations. Scope of this chapter is limited to one of the soft computing optimizing techniques that is artificial neural network (ANN) and to one of the unconventional machining processes, electrical discharge machining process. This chapter discusses about micromachining on Electric Discharge Machining, its working principle and problems associated with it. Solution to those problems is suggested with the addition of powder in dielectric fluid. The optimization of Material Removal Rate (MRR) is done with the help of ANN toolbox in MATLAB.

Study of Machine Characteristics During Rotary EDM Machining using Tools Made of Aluminium Alloy 6061

Electro discharge machining (EDM) is an unconventional machining process that uses spark energy to remove material from the workpiece. EDM process is extensively being used in die/mould making industries, automobile industry, aerospace industry etc. for generating complex and intricate shape on hard material. Numbers of research works have been carried out using EDM process in order to improve the performance. Further, different variant of EDM process like dry EDM, orbital EDM, powder mixed EDM, ultrasonic assisted EDM and rotary EDM etc. have also been studied. Rotary EDM process is very promising process that helps to improve surface finish, overcut as well as out of roundness. In the present paper, a extensive review has been presented on rotary EDM process. Significance of several input parameters has been observed on output characteristics like overcut and out of roundness.

EXPERIMENTAL INVESTIGATION OF MICRO-EDM OPERATION IN INCONEL 718

The increasing trends towards miniaturized and lightweight components for various engineering and aerospace applications by unconventional machining the demand for micro-electrical discharge machining (EDM) have become increasingly wide. Micro-EDM is one of the most promising unconventional machining processes as compared to other unconventional machining due to its lower cost, ease of operation, and accuracy. This research explores the experimental investigation of micro-EDM operation on hard and difficult to machine material Inconel 718. The micro-holes were fabricated on an Inconel 718 workpiece with a copper electrode. The influence of input process parameters on material removal rate (MRR), machining time, and quality of the fabricated micro-holes were studied. Overcut and taperness of the fabricated micro-sized through holes were measured to address the accuracy of the fabricated micro-holes in micro-EDM operation. Experimental results reveal that the increase in current and voltage increases the MRR, and reduced machining time but at the cost of dimensional accuracy of the fabricated holes. The high value of current and voltage resulted in poor surface quality. The optimum machining condition that gives higher MRR with higher machining precision was obtained by experimenting while machining Inconel 718.

OVERVIEW OF MATERIAL PROCESSING MECHANISMS IN UNCONVENTIONAL MACHINING METHOD

From the point of view of the concept itself, technology is a set of processes, rules and habits used in the production of various objects in the most diverse spheres of production, or human activity itself. Therefore, there are several designations and naming of production technologies in the professional literature. Historically, probably the oldest systematic designation and division of production technologies and processes is given as early as 1963 in the German standard: Begriffe der Fertigungsverfahren DIN 8580. The standard defines production processes for the production of geometrically certain solids. In the paper is shown explanations of mechanisms of machining when is used unconventional machining technologies.