scholarly journals Multi-Performance Optimization in Electrical Discharge Machining of Al2O3 Ceramics Using Taguchi Base AHP Weighted TOPSIS Method

Processes ◽  
2021 ◽  
Vol 9 (9) ◽  
pp. 1647
Author(s):  
Yue-Peng Zeng ◽  
Chiang-Lung Lin ◽  
Hong-Mei Dai ◽  
Yan-Cherng Lin ◽  
Jung-Chou Hung
Keyword(s):  
Process Parameters ◽  
Performance Optimization ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Technique ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Relative Closeness ◽  
Machining Parameter

The main application of electrical discharge machining in ceramic processing is limited to conductive ceramics. However, the most commonly used non-conductive potteries in modern industry, such as aluminum oxide (Al2O3), also reveal the limitations of choosing a suitable process. In this study, Taguchi based TOPSIS coupled with AHP weight method to optimize the machining parameters of EDM on Al2O3 leads to better multi-performance. The results showed that the technique is suitable for tackling multi-performance machining parameter optimization. The adhesive foil had a significant impact on material removal rate, electrode wear rate, and surface roughness, according to the findings. In addition, the response graph of relative closeness is used to determine the optimal combination levels of machining parameters. A confirmation test revealed a good agreement between predicted and experimental preference values at an optimum combination of the input parameters. The suggested experimental and statistical technique is a simple, practical, and reliable methodology for optimizing EDM process parameters on Al2O3 ceramics. This approach might be utilized to optimize and improve additional process parameters in the future.

Optimization of Multiple Performances for EDM in Gas Media Using Grey Relational Analysis

2014 ◽  
Vol 620 ◽  
pp. 173-178
Author(s):  
Fang Pin Chuang ◽  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
A. Cheng Wang
Keyword(s):  
Grey Relational Analysis ◽  
Electrical Discharge Machining ◽  
Design Method ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Relational Analysis ◽  
Grey Relational ◽  
Machining Parameter

The aim of this investigation is to optimize the multiple performance characteristics of electrical discharge machining (EDM) for SKD 61 tool steel in gas media using grey relational analysis. The three most important machining characteristics namely material removal rate (MRR), electrode wear rate (EWR), and surface roughness (SR) were considered as the measures of the performance characteristics. A series of experiments were conducted according to an L18 orthogonal array based on the Taguchi experimental design method. The observed data obtained from the experiments were evaluated to determine the optimization of machining parameters correlated with multiple performance characteristics through grey relational analysis. Moreover, analysis of variance (ANOVA) was conducted to explore the significant machining parameters crucially affecting the multiple performance characteristics. In addition, the optimal combination levels of machining parameters were also determined from the response graph of grey relational grades for each level of machining parameter.

Reducing Electrode Wear Using Cryogenic Cooling during Electrical Discharge Machining

2009 ◽  
Vol 83-86 ◽  
pp. 672-679 ◽  
Author(s):  
Suleiman Abdulkareem ◽  
Ahsan Ali Khan ◽  
Mohamed Konneh
Keyword(s):  
Electrode Material ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Cryogenic Cooling ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Electrode Tool ◽  
Pulse On Time

In electrical discharge machining (EDM), material is removed by a series of electrical discharge between the electrode (tool) and the workpiece that develops a temperature of about 8,0000C to 12,0000C. Due to high temperature of the sparks, work material is melted and vapourized, at the same time the electrode material is also eroded by melting and vapourization. Electrodes wear (EW) process is quite similar to the material removal mechanism as the electrode and the workpiece are considered as a set of electrode in EDM. In the present study effort has been made to reduce EW by cooling, using liquid nitrogen during the EDM of titanium alloy. Investigation on the effect of cooling on electrode wear (EW), material removal rate (MRR) and surface roughness (Ra) of the workpiece was carried out. Current (I), pulse on-time (ton), pause off-time (toff) and voltage (v) were considered as the machining parameters. Design of experiment (DOE) was used to design the experimental works. Cooling of electrode by this technique reduced the melting and vapourization of electrode material and enhances electrode life. It was possible to reduce EW up to 27% by applying this technique while MRR and Ra were improved by 18% and 8% respectively.

scholarly journals Effects of Side Flushing and Multi-Aperture Inner Flushing on Characteristics of Electrical Discharge Machining Macro Deep Holes

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 148
Author(s):  
Suppawat Chuvaree ◽  
Kannachai Kanlayasiri
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Machining Performance ◽  
Electrode Rotation ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Off Time

This research investigates the effect of machining parameters on material removal rate, electrode wear ratio, and gap clearance of macro deep holes with a depth-to-diameter ratio over four. The experiments were carried out using electrical discharge machining with side flushing and multi-aperture flushing to improve the machining performance and surface integrity. The machining parameters were pulse on-time, pulse off-time, current, and electrode rotation. Response surface methodology and the desirability function were used to optimize the electrical discharge machining parameters. The results showed that pulse on-time, current, and electrode rotation were positively correlated with the material removal rate. The electrode wear ratio was inversely correlated with pulse on-time and electrode rotation but positively correlated with current. Gap clearance was positively correlated with pulse on-time but inversely correlated with pulse off-time, current, and electrode rotation. The optimal machining condition of electrical discharge machining with side flushing was 100 µs pulse on-time, 20 µs pulse off-time, 15 A current, and 70 rpm electrode rotation; and that of electrical discharge machining with multi-aperture flushing was 130 µs, 2 µs, 15 A, and 70 rpm. The novelty of this research lies in the use of multi-aperture flushing to improve the machining performance, enable a more uniform GC profile, and minimize the incidence of recast layer.

scholarly journals Using a Fuzzy Inference System to Obtain Technological Tables for Electrical Discharge Machining Processes

Mathematics ◽  
2020 ◽  
Vol 8 (6) ◽  
pp. 922 ◽  
Author(s):  
C. J. Luis Pérez
Keyword(s):  
Fuzzy Inference System ◽  
Electrical Discharge ◽  
Material Removal ◽  
Fuzzy Inference ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Operating Conditions ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Inference System

Technological tables are very important in electrical discharge machining to determine optimal operating conditions for process variables, such as material removal rate or electrode wear. Their determination is of great industrial importance and their experimental determination is very important because they allow the most appropriate operating conditions to be selected beforehand. These technological tables are usually employed for electrical discharge machining of steel, but their number is significantly less in the case of other materials. In this present research study, a methodology based on using a fuzzy inference system to obtain these technological tables is shown with the aim of being able to select the most appropriate manufacturing conditions in advance. In addition, a study of the results obtained using a fuzzy inference system for modeling the behavior of electrical discharge machining parameters is shown. These results are compared to those obtained from response surface methodology. Furthermore, it is demonstrated that the fuzzy system can provide a high degree of precision and, therefore, it can be used to determine the influence of these machining parameters on technological variables, such as roughness, electrode wear, or material removal rate, more efficiently than other techniques.

Experimental Research on Technology of Ultrasonic Vibration Aided Electrical Discharge Machining (UEDM) in Gas

2006 ◽  
Vol 315-316 ◽  
pp. 81-84 ◽  
Author(s):  
Qin He Zhang ◽  
Jian Hua Zhang ◽  
Q.B. Zhang ◽  
Shu Peng Su
Keyword(s):  
Ultrasonic Vibration ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Environment Pollution ◽  
Dielectric Fluids

Ultrasonic vibration aided electrical discharge machining (UEDM) in gas is an electrical discharge machining (EDM) technology, in which gases such as air and oxygen are used as dielectrics and ultrasonic vibration is applied. UEDM in gas can avoid environment pollution, the most serious disadvantage of conventional EDM in kerosene-based oil or other dielectric fluids, and it is environmental-friendly. The technology also possesses virtues of wide applications, high machining efficiency and simple tool electrodes and so on. The principle of UEDM in gas is introduced in this paper. Experiments have been carried out to study the effects of machining parameters on material removal rate (MRR), surface roughness of the workpiece and tool electrode wear ratio (TWR), and the experiments results have also been analyzed.

Optimization of Machining Parameters Using EDM in Gas Media Based on Taguchi Method

2012 ◽  
Vol 459 ◽  
pp. 170-175 ◽  
Author(s):  
Der An Wang ◽  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Shih Feng Fan ◽  
A Cheng Wang
Keyword(s):  
Taguchi Method ◽  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Pressure Peak ◽  
Machining Parameter ◽  
Machining Characteristics

The aim of this study is to investigate the machining characteristics of gas media used in electrical discharge machining (EDM). The process parameters were designed based on Taguchi method to manage the experimental work. The main process parameters such as machining polarity, gas pressure, peak current, pulse duration, type of gas media, and servo reference voltage were adopted to explore their effects on machining performance in terms of material removal rate (MRR) and surface roughness (SR) for SKD 61 tool steel. The experimental observed values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters affecting obviously the machining performance were determined by analysis of variance (ANOVA). The optimal combination level of machining parameter for each machining characteristic was obtained by the S/N ratio analysis according to Taguchi methodology.

scholarly journals Optimizing Main Process Parameters When Conducting Powder-Mixed Electrical Discharge Machining of Hardened 90CrSi

Machines ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 375
Author(s):  
Anh-Tuan Nguyen ◽  
Xuan-Hung Le ◽  
Van-Tung Nguyen ◽  
Dang-Phong Phan ◽  
Quoc-Hoang Tran ◽  
...  
Keyword(s):  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Optimization Process ◽  
Main Process ◽  
Electrode Wear ◽  
Powder Concentration ◽  
Pulse On Time ◽  
Pulse Off Time

In the current study, an optimization process of powder-mixed electrical discharge machining (PMEDM) process when machining cylindrically shaped parts made of hardened 90CrSi steel is reported. In this study, SiC powder was mixed into the Diel MS 7000 dielectric solution. Additionally, graphite was chosen as the electrode material. The multi-objective functions were minimizing the surface roughness (SR) and electrode wear rate (EWR) and maximizing the material removal rate (MRR). The used input parameters of the optimization process included the powder concentration, the pulse-on time, the pulse-off time, the pulse current, and the servo voltage. A combination between the Taguchi method and the grey relation analysis (GRA) method with the support of Minitab R19 software was used to design the experiment and analyze the results. It was found that the optimal set of process parameters that can satisfy the above responses are Cp of 0.5 g/L, Ton of 8 µs, Toff of 8 µs, IP of 5 A, and SV of 4 V.

Optimisation of Machining Parameters in Electrical Discharge Machining of LM25-RHA Composites

2017 ◽  
pp. 1-18
Author(s):  
Srikant Tiwari ◽  
Mohan Kumar Pradhan
Keyword(s):  
Conventional Method ◽  
Rice Husk ◽  
Electrical Discharge ◽  
Rice Husk Ash ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Electrode Wear ◽  
Machining Parameters ◽  
Optimal Setting

Aluminium composites are tough to machine by using conventional method. In order to increase machinability of aluminium-based composite a non-conventional method of machining has been used. Electrical Discharge Machining (EDM) is one of the kind of machining process which has often uses for machining of aluminium composites. The objective of this chapter is to determine the ideal setting of the process parameters on the electrical discharge machining while machining Aluminium-Rice Husk Ash (LM25-RHA) composites in which three different variation (4%, 8%, 12%) of Rice Husk Ash has been used. The parameters considered are pulse current (Ip), gap voltage (V) and pulse-on-time (Ton); whereas its effect are analysed on Electrode Wear Rate (EWR), Material Removal Rate (MRR) and Surface Roughness (Ra). The optimal setting of the parameters are determined through experiments planned, conducted and analysed using the Taguchi method.

Application of Desirability Analysis for Optimizing the Micro Wire Electrical Discharge Machining (μWEDM) Parameters

2014 ◽  
Vol 592-594 ◽  
pp. 77-81 ◽  
Author(s):  
M. Santhanakumar ◽  
R. Adalarasan ◽  
M. Rajmohan
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Quality Characteristics ◽  
Wire Electrical Discharge Machining ◽  
Machining Parameters ◽  
Desirability Analysis ◽  
Machining Parameter ◽  
Wire Feed

Close tolerance and precision requirements of biomedical components and miniaturization of sensors has given micro wire electrical discharge machining (μWEDM) a substantial amount of research attention. The process parameters like gap voltage, capacitance, wire feed rate and wire tension play an important role in influencing the quality characteristics of the machined parts. The challenge lies in selecting the optimal machining parameter combination to achieve the desired surface finish and metal removal rate in a multi input multi output process like μWEDM. The process parameters were varied at three levels and Taguchi’s L9 orthogonal array was used to design and conduct the experiments. Desirability analysis was applied for predicting the optimal setting of machining parameters and ANOVA results had revealed the significant role of wire feed rate and gap voltage in affecting the quality characteristics of the process

Optimization and surface modification in electrical discharge machining of AA 6061/SiCp composite using Cu–W electrode

2015 ◽  
Vol 231 (3) ◽  
pp. 332-348 ◽  
Author(s):  
Balbir Singh ◽  
Jatinder Kumar ◽  
Sudhir Kumar
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Electrode Wear ◽  
Material Transfer ◽  
Machined Surface ◽  
Recast Layer Thickness ◽  
Pulse On Time ◽  
Pulse Off Time

This paper presents the experimental investigation on the electro-discharge machining of aluminum alloy 6061 reinforced with SiC particles using sintered Cu–W electrode. Experiments have been designed as per central composite rotatable design, using response surface methodology. Machining characteristics such as material removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR) have been investigated under the influence of four electrical process parameters; namely peak current, pulse on time, pulse off time, and gap voltage. The process parameters have been optimized to obtain optimal combination of MRR, EWR, and SR. Further, the influence of sintered Cu–W electrode on surface characteristics has been analyzed with scanning electron microscopy, energy dispersive spectroscopy, and Vicker microhardness tests. The results revealed that all the process parameters significantly affect MRR, EWR, and SR. The machined surface properties are modified as a result of material transfer from the electrode. The recast layer thickness is increased at higher setting of electrical parameters. The hardness across the machined surface is also increased by the use of sintered Cu–W electrode.

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