Study on Machinabilty of Al2O3 Ceramic Composite in EDM Using Response Surface Methodology

2011 ◽  
Vol 133 (2) ◽  
Author(s):  
K. M. Patel ◽  
Pulak M. Pandey ◽  
P. Venkateswara Rao
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Current Pulse ◽  
Duty Cycle ◽  
Discharge Current ◽  
Ceramic Composite ◽  
Electrode Wear ◽  
Discharge Current Pulse ◽  
Pulse On Time

Electric discharge machining (EDM) has been proven as an alternate process for machining complex and intricate shapes from the conductive ceramic composites. Al2O3 based electrodischarge machinable Al2O3–SiCw–TiC ceramic composite is a potential substitute for traditional materials due to their high hardness, excellent chemical, and mechanical stability under a broad range of temperature, and high specific stiffness. The right selection of the machining condition is the most important aspect to take into consideration in the EDM. The present work correlates the inter-relationships of various EDM machining parameters, namely, discharge current, pulse-on time, duty cycle, and gap voltage on the metal removal rate (MRR), electrode wear ratio (EWR), and surface roughness using the response surface methodology (RSM) while EDM of Al2O3–SiCw–TiC ceramic composite. Analysis of variance is used to study the significance of process variables on MRR, EWR, and surface roughness. The experimental results reveal that discharge current, pulse-on time, and duty cycle significantly affected MRR and EWR, while discharge current and pulse-on time affected the surface roughness. The validation of developed models shows that the MRR EWR and surface roughness of EDM of Al2O3–SiCw–TiC ceramic can be estimated with reasonable accuracy using the second-order models. Finally, trust-region method for nonlinear minimization is used to find the optimum levels of the parameters. The surface and subsurface damage have also been assessed and characterized using scanning electron microscopy. This study reveals that EDMed material unevenness increases with discharge current and pulse-on time.

scholarly journals Relevance Vector Machine Based Analyses of MRR and SR of Electrodischarge Machining Designed by Response Surface Methodology

2013 ◽  
Vol 2013 ◽  
pp. 1-9 ◽  
Author(s):  
Kanhu Charan Nayak ◽  
Rajesh Kumar Tripathy ◽  
Sudha Rani Panda
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Duty Cycle ◽  
Discharge Current ◽  
Removal Rate ◽  
Relevance Vector Machine ◽  
Machining Process ◽  
Machining Parameters ◽  
Electrodischarge Machining ◽  
Pulse On Time

Relevance vector machine is found to be one of the best predictive models in the area of pattern recognition and machine learning. The important performance parameters such as the material removal rate (MRR) and surface roughness (SR) are influenced by various machining parameters, namely, discharge current (Ip), pulse on time (Ton), and duty cycle (tau) in the electrodischarge machining process (EDM). In this communication, the MRR and SR of EN19 tool steel have been predicted using RVM model and the analysis of variance (ANOVA) results were performed by implementing response surface methodology (RSM). The number of input parameters used for the RVM model is discharge current (Ip), pulse on time (Ton), and duty cycle (tau). At the output, the corresponding model predicts both MRR and SR. The performance of the model is determined by regression test error which can be obtained by comparing both predicted MRR and SR from model and experimental data is designed using central composite design (CCD) based RSM. Our result shows that the regression error is minimized by using cubic kernel function based RVM model and the discharge current is found to be one of the most significant machining parameters for MRR and SR from ANOVA.

Performance Evaluation on Cryogenic Cooling of Electrode in Electrical Discharge Machining in AISI D2 Steel

2013 ◽  
Author(s):  
M. Pradeep Kumar ◽  
S. Vinoth Kumar
Keyword(s):  
Surface Roughness ◽  
Current Pulse ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Electrode Wear ◽  
Machined Surface ◽  
Aisi D2 ◽  
Pulse On Time ◽  
D2 Steel

This research has been conducted to evaluate the performance of the Liquid Nitrogen (LN2) cooling of copper electrode in electrical discharge machining (EDM) on AISI D2 steel. The experimental process parameter such as discharge current, pulse on time and gap voltage were varied to explore their effects on machining performance, including the electrode wear and surface roughness. It was found that for electrode wear, discharge current, pulse on time, and gap voltage has the most significant effect, while the pulse on time and discharge current have the most significant effect on surface roughness. Analysis on the influence of cooling responses has been carried out and presented in this study. It was found that the electrode wear reduced up to 18% during LN2 cooling. Surface roughness was also significantly reduced while machining with LN2 electrode cooling. Scanning electron microscope (SEM) analysis was carried out to study the surface characteristics of machined surface. EDMed machined surface was also acceptable in LN2 cooling of the electrode.

scholarly journals Material Removal Rate, Electrode Wear Rate, and Surface Roughness Evaluation in Die Sinking EDM with Hollow Tool through Response Surface Methodology

2014 ◽  
Vol 2014 ◽  
pp. 1-16 ◽  
Author(s):  
Teepu Sultan ◽  
Anish Kumar ◽  
Rahul Dev Gupta
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Wear Rate ◽  
Response Surface ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrode Wear ◽  
Electrode Wear Rate ◽  
Pulse On Time

Electrical discharge machining is one of the earliest nontraditional machining, extensively used in industry for processing of parts having unusual profiles with reasonable precision. In the present work, an attempt has been made to model material removal rate, electrode wear rate, and surface roughness through response surface methodology in a die sinking EDM process. The optimization was performed in two steps using one factor at a time for preliminary evaluation and a Box-Behnken design involving three variables with three levels for determination of the critical experimental conditions. Pulse on time, pulse off time, and peak current were changed during the tests, while a copper electrode having tubular cross section was employed to machine through holes on EN 353 steel alloy workpiece. The results of analysis of variance indicated that the proposed mathematical models obtained can adequately describe the performances within the limits of factors being studied. The experimental and predicted values were in a good agreement. Surface topography is revealed with the help of scanning electron microscope micrographs.

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

2021 ◽  
pp. 095440892110414
Author(s):  
TS Senthilkumar ◽  
R Muralikannan ◽  
T Ramkumar ◽  
S Senthil Kumar
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Kerf Width ◽  
Wire Electrical Discharge Machining ◽  
Box Behnken Design ◽  
Pulse On Time

A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

Optimization of process parameters in magnetic field assisted powder mixed EDM of aluminium 6061 alloy

2020 ◽  
pp. 095440622095910
Author(s):  
Arun Kumar Rouniyar ◽  
Pragya Shandilya
Keyword(s):  
Magnetic Field ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Discharge Current ◽  
Electrical Discharge Machining ◽  
Desirability Function ◽  
Fine Powder ◽  
Quadratic Model ◽  
Electrode Wear

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is a variant of EDM process where magnetic field coupled with electric field is used with addition of fine powder in dielectric to improve the surface quality, machining rate and stability of the process. Aluminium 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In this present work, parametric study and optimization was carried out on MFAPM-EDM machined Aluminium 6061 alloy. In this study, process parameters such as discharge current (IP), spark duration (PON), pause duration (POFF), concentration of powder (CP) and magnetic field (MF) were considered to analyze the effect on material erosion rate (MER) and electrode wear rate (EWR). Box Behnken design approach based on response surface methodology (RSM) was utilized for performing the experiments. Quadratic model to predict the MER and EWR were developed using response surface methodology. Discharge current has most significant effect of 50.176% and 36.36% on MER and EWR, respectively among all others process parameters. Teacher-learning-based optimization (TLBO) was employed for determining the optimal process parameters for maximum MER and minimal EWR. The results obtained with TLBO was compared with well-known optimization methods such as genetic algorithm (GA) and desirability function of RSM. Minimum EWR (0.1021 mm3/min) and maximum MER (30.4687 mm3/min) obtained using TLBO algorithm for optimized process parameters was found to better as compared to GA and desirability function.

Experimental Investigation of Process Parameters in Wire Electrical Discharge Machining by Response Surface Methodology on IS2062 Steel

2014 ◽  
Vol 550 ◽  
pp. 53-61
Author(s):  
R.Arun Bharathi ◽  
P.Ashoka Varthanan ◽  
K. Manoj Mathew
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Machining Parameters ◽  
Peak Current ◽  
Custom Design ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

The objective of the present work is to predict the optimal set of process parameters such as peak current (IP), pulse on/off time (TON/TOFF) and spark gap voltage (SV) to achieve minimum Surface roughness (Ra), wire consumption rate (WCR) and maximum material removal rate (MRR). In this work, experiments were carried out by pulse arc discharges generated between ZnO coated brass wire and specimen (IS2062 steel) suspended in deionized water dielectric. The experiments were designed based on the above mentioned four factors, each having three levels. Custom design based Response Surface Methodology (RSM) is used in this research. 21 runs of experiments were constructed based on custom design procedure and results of the experimentation were analyzed analytically as well as graphically. Moreover the surface roughness after machining was measured by Taylor Hobson Surtronic device. Second order regression model has been developed for predicting Ra, WCR and MRR in terms of interactive and higher order machining parameters through RSM, utilizing relevant experimental data as obtained through experimentation. The research outcome identifies significant parametersand their effect on process performance on IS2062 steel. The results revealed that peak current, pulse on-time and their interactions have significant effects on Ra, whereas pulse off time and peak current have significant effects on MRR and it is also observed that peak current and interaction between peak current and pulse off time have significant effects on WCR. The adequacy of the above proposed models has been tested through the analysis of variance (ANOVA).

scholarly journals Optimization of the Material Removal Rate and Electrode Wear Ratio in Electrical Discharge Machining of Reaction-bonded Silicon Carbide by Response Surface Methodology

2020 ◽  
Vol 9 (4) ◽  
pp. 2116-2120
Keyword(s):  
Silicon Carbide ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
High Hardness ◽  
Electrode Wear ◽  
Good Surface ◽  
Pulse On Time

Reaction-bonded silicon carbide (RB-SiC) is widely used as moulding dies material in many industries thanks to its excellent properties. Nevertheless, because of its high hardness and brittleness, it is extremely hard to be machined with high accuracy and good surface finish. Therefore, electrical discharge machining (EDM) has been chosen as an alternative method to machine the RB-SiC. In the present study, an experimental investigation has been conducted to optimize and validate the EDM parameters on the MRR and EWR of low conductivity RB-SiC in EDM. The new Cu – 1.0 wt. % CNF composite electrode that fabricated via powder metallurgy (PM) process was used as the electrode. The experiments were systematically conducted by face-cubic centre (FCC) approach of response surface methodology (RSM). The mathematical models for MRR and EWR were developed in this study. In addition, analysis of variance (ANOVA) was also figured out to check the significance of the models. Three experiments were conducted as the confirmation test to determine the error percentage of MRR and EWR. Based on the results, only 3.06% and 3.93% errors were determined for both MRR and EWR, respectively. The optimum conditions for multi responses (MRR and EWR) were found to be at a current of 6A, voltage of 22V, and pulse on-time of 12µs. The findings of this study provide an important reference to the manufacturing industries, especially mould and die industry.

Effect of process parameters on the electrical discharge machining of aluminum metal matrix composites through a response surface methodology approach

2016 ◽  
Vol 23 (2) ◽  
pp. 145-154
Author(s):  
V. Balasubramaniam ◽  
N. Baskar ◽  
Chinnaiyan Sathiya Narayanan
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Matrix Composites ◽  
Current Pulse ◽  
Process Parameters ◽  
Metal Matrix ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Matrix Composites ◽  
Pulse On Time

AbstractThis work presents the multiobjective optimization of machining parameters during the electrical discharge machining (EDM) of aluminum (Al)-silicon carbide (SiC) metal matrix composites (MMC). The process parameters considered were current, pulse on-time, dielectric flushing pressure, and SiC particles. A copper rod was used as an electrode. An Al-SiC MMC with Al 6061 as matrix and SiC particles having three different sizes (i.e., 15, 25, and 40 μm) were used as workpieces. The experiments were planned using design of experiments through response surface methodology (RSM). The mathematical models were developed to predict the better performance measures such as the material removal rate (MRR), electrode wear rate (EWR), surface roughness (SR), and cylindricity (CY). The desirability approach in RSM was performed for optimization. It was found that the MRR increases with increasing peak current, pulse on-time, flushing pressure, and particle size. The EDM parameters are to be analyzed for the MRR, EWR, SR, and CY. The best one is proposed for validation.

Parametric Optimization of Boron Carbide Powder Added Electrical Discharge Machining of Titanium Alloy

2014 ◽  
Vol 592-594 ◽  
pp. 678-683 ◽  
Author(s):  
Murahari Kolli ◽  
Adepu Kumar
Keyword(s):  
Titanium Alloy ◽  
Boron Carbide ◽  
Current Pulse ◽  
Discharge Current ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Taguchi Technique ◽  
Discharge Current Pulse ◽  
Powder Concentration ◽  
Pulse On Time

The present study deals with the Taguchi technique applied to determine the optimal process parameters of Boron Carbide (B4C) powder mixed electrical discharge machining (EDM) of Titanium alloy. The performance characteristics like material removal rate (MRR) and surface roughness (SR) were experimentally explored for various input parameters such as discharge current, pulse on time, pulse off time and B4C powder concentration in dielectric fluid. The planned optimal setting parameters were conducted and verified through experiments and analyzed using Taguchi technique. Analysis of variance (ANOVA) revealed that discharge current, pulse on time and B4C powder concentration in dielectric are most important parameters affecting both the performance parameters.

INVESTIGATION OF EFFECTS OF DIELECTRIC TYPE AND POLARITY ON ELECTRIC DISCHARGE MACHINING OF AISI D2 STEEL USING RESPONSE SURFACE METHODOLOGY

2019 ◽  
Vol XVI (4) ◽  
pp. 81-93
Author(s):  
Muhammad Hanif ◽  
Wasim Ahmad ◽  
Salman Hussain ◽  
Mirza Jahanzaib
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electric Discharge ◽  
Discharge Current ◽  
Removal Rate ◽  
Electric Discharge Machining ◽  
Aisi D2 Steel ◽  
Aisi D2 ◽  
D2 Steel

This paper presents a study on optimisation of process parameters of die-sinking electric discharge machining. The influence of dielectric type, electrode polarity, discharge current and gap on the material removal rate (MRR) and surface roughness for machining of AISI D2 steel have been studied. Response surface methodology suggested in the existing literature was employed for conducting the experiments. Kerosene and transformer oils were found as the best dielectric for MRR and surface roughness, respectively. It was also found that electrode with positive polarity offers high MRR while negative polarity ensures best surface finish. ANOVA results indicated that discharge current was the most influencing factor affecting the performance measures, MRR and surface roughness. Although discharge gap showed low effect on MRR and surface roughness, it was effective for debris removal. Empirical models were developed to optimise the results of MRR and surface roughness.

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