scholarly journals Modelling and experimental investigation of process parameters in WEDM of WC-5.3 % Co using response surface methodology

2012 ◽  
Vol 3 (2) ◽  
pp. 63-72 ◽  
Author(s):  
K. Jangra ◽  
S. Grover
Keyword(s):  
Experimental Data ◽  
Experimental Investigation ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge Machining ◽  
Cutting Speed ◽  
Performance Characteristics ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Factor Interaction

Abstract. Tungsten carbide-cobalt (WC-Co) composite is a difficult-to-machine material owing to its excellent strength and hardness at elevated temperature. Wire electrical discharge machining (WEDM) is a best alternative for machining of WC-Co composite into intricate and complex shapes. Efficient machining of WC-Co composite on WEDM is a challenging task since it involves large numbers of parameters. Therefore, in present work, experimental investigation has been carried out to determine the influence of important WEDM parameters on machining performance of WC-Co composite. Response surface methodology, which is a collection of mathematical and experimental techniques, was utilised to obtain the experimental data. Using face-centered central composite design, experiments were conducted to investigate and correlate the four input parameters: pulse-on time, pulse-off time, servo voltage and wire feed for three output performance characteristics – cutting speed (CS), surface roughness (SR) and radial overcut (RoC). Using analysis of variance on experimental data, quadratic vs. two-factor interaction (2FI) models have been suggested for CS and RoC while two-factor interaction (2FI) has been proposed for SR. Using these mathematical models, optimal parameters can be determined easily for desired performance characteristics, and hence a trade-off can be made among different performance characteristics.

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.

scholarly journals MODELLING AND OPTIMIZATION OF PERFORMANCE CHARACTERISTICS IN ELECTRICAL DISCHARGE MACHINING ON TITANIUM ALLOY

2013 ◽  
Vol 43 (1) ◽  
pp. 33-40
Author(s):  
Md. Ashikur Rahman Khan
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Short Pulse ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Pulse Interval ◽  
Hard Material ◽  
Set Up ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining (EDM) technique possesses noticeable advantages over othermachining process and can machine any hard material effectively. Proper selection of parameters in EDM isvery much essential to achieve better performance characteristics that are still challenging. This study attemptsto investigate the effects of parameters on EDM performance characteristics on Ti-6Al-4V utilizing coppertungsten as electrode and negative polarity of the electrode. Mathematical model associating the influences ofthese variables and the EDM characteristics such as material removal rate (MRR) and tool wear rate (TWR)are set up in this study. The optimal machining conditioning in favor of MRR and TWR are estimated. Design ofexperiments method and response surface methodology techniques are adopted to attain the objectives. Analysisof variance (ANOVA) has been performed for the validity test of the fit and adequacy of the proposed models.Optimum MRR is found at high discharge ampere, long pulse on time and short pulse off time. 8A peak current,10 ?s pulse on time and 184 ?s pulse interval yields lowest TWR. The result of this investigation guides torequired process outputs and economical industrial machining optimizing the input factors.DOI: http://dx.doi.org/10.3329/jme.v43i1.15778

scholarly journals Integration of Fuzzy AHP and Fuzzy TOPSIS Methods for Wire Electric Discharge Machining of Titanium (Ti6Al4V) Alloy Using RSM

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7408
Author(s):  
Kishan Fuse ◽  
Arrown Dalsaniya ◽  
Dhananj Modi ◽  
Jay Vora ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Fuzzy Ahp ◽  
Cutting Speed ◽  
High Hardness ◽  
Fuzzy Topsis ◽  
Ti6al4v Alloy ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

Titanium and its alloys exhibit numerous uses in aerospace, automobile, biomedical and marine industries because of their enhanced mechanical properties. However, the machinability of titanium alloys can be cumbersome due to their lower density, high hardness, low thermal conductivity, and low elastic modulus. The wire electrical discharge machining (WEDM) process is an effective choice for machining titanium and its alloys due to its unique machining characteristics. The present work proposes multi-objective optimization of WEDM on Ti6Al4V alloy using a fuzzy integrated multi-criteria decision-making (MCDM) approach. The use of MCDM has become an active area of research due to its proven ability to solve complex problems. The novelty of the present work is to use integrated fuzzy analytic hierarchy process (AHP) and fuzzy technique for order preference by similarity to ideal situation (TOPSIS) to optimize the WEDM process. The experiments were systematically conducted adapting the face-centered central composite design approach of response surface methodology. Three independent factors—pulse-on time (Ton), pulse-off time (Toff), and current—were chosen, each having three levels to monitor the process response in terms of cutting speed (VC), material removal rate (MRR), and surface roughness (SR). To assess the relevance and significance of the models, an analysis of variance was carried out. The optimal process parameters after integrating fuzzy AHP coupled with fuzzy TOPSIS approach found were Ton = 40 µs, Toff = 15 µs, and current = 2A.

Multicut technology used in WEDM machining of Mar-M247

2021 ◽  
pp. 095440542110434
Author(s):  
Katerina Mouralova ◽  
Ales Polzer ◽  
Libor Benes ◽  
Josef Bednar ◽  
Radim Zahradnicek ◽  
...  
Keyword(s):  
Electrical Discharge Machining ◽  
Subsurface Layer ◽  
Cutting Speed ◽  
Complete Removal ◽  
Nickel Superalloy ◽  
Machined Surface ◽  
The Third ◽  
Optimal Setting ◽  
Pulse On Time ◽  
Pulse Off Time

Wire electrical discharge machining (WEDM) technology is often used for the final machining of parts to the required surface quality without further finishing operations. At the same time, WEDM has a significant advantage over other machining technologies, and in the fact, it is possible to machine all materials, regardless of their hardness or toughness, it only needs to be at least electrically conductive. Aviation nickel superalloy Mar-M247, which is usually machined to the final form by parts using WEDM, was the subject of research in this study. In order to find the optimal setting of machine parameters (Pulse on time, Pulse off time, and Discharge current) for multicut machining, an extensive design of experiment was performed with a total of 54 circles, which optimized the cutting speed in the first and second cuts and the topography of the machined surface was taken into account in the third cut. Subsequently, an analysis of the topography and morphology of the machined samples was performed, including an analysis of the condition of the subsurface layer. The study also included the analysis of the lamella in a transmission electron microscope. It was found that with the maximization of the cutting speed in the third cut, the surface topography deteriorates proportionally, but it also leads to the complete removal of all cracks formed in the first cut.

OPTIMIZATION OF ELECTRICAL DISCHARGE MACHINING PARAMETERS OF SISIC THROUGH RESPONSE SURFACE METHODOLOGY

2016 ◽  
Vol 79 (1) ◽  
Author(s):  
Abdul Azeez Abdu Aliyu ◽  
Jafri Mohd Rohani ◽  
Ahmad Majdi Abdul Rani ◽  
Hamidon Musa
Keyword(s):  
Silicon Carbide ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Industrial Applications ◽  
Machining Parameters ◽  
Difficult Time ◽  
Pulse On Time

In recent years, researchers have demonstrated increases interest in studies involving silicon carbide (SiC) materials due to several industrial applications. Extreme hardness and high brittleness properties of SiC make the machining of such material very difficult, time consuming and costly. Electrical discharge machining (EDM) has been regarded as the most viable method for the machining of SiC. The mechanism of EDM process is complex. Researchers have acknowledged a challenge in generating a model that accurately describes the correlation between the input parameters and the responses. This paper reports the study on parametric optimization of siliconized silicon carbide (SiSiC) for the following quality responses; material removal rate (MRR), tool wear ratio (TWR) and surface roughness (Ra). The experiments were planned using Face centered central composite design. The models which related MRR, TWR and Ra with the most significant factors such as discharge current (Ip), pulse-on time (Ton), and servo voltage (Sv) were developed. In order to develop, improve and optimize the models response surface methodology (RSM) was used. Non-linear models were proposed for MRR and Ra while linear model was proposed for TWR. The margin of error between predicted and experimental values of MRR, TWR and Ra are found within 6.7, 5.6 and 2.5% respectively. Thus, the excellent reproducibility of this experimental study is confirmed, and the models developed for MRR, TWR and Ra are justified to be valid by the confirmation tests.

Multi-Response Optimization of Machining Process Parameters for Wire Electrical Discharge Machining of Lead-Induced Ti-6Al-4V Alloy Using AHP–TOPSIS Method

2019 ◽  
Vol 18 (02) ◽  
pp. 213-236 ◽  
Author(s):  
A. V. S. Ram Prasad ◽  
Koona Ramji ◽  
Murahari Kolli ◽  
G. Vamsi Krishna
Keyword(s):  
Process Parameters ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Performance Characteristics ◽  
Machining Process ◽  
Analytic Hierarchy ◽  
Response Characteristics ◽  
Multi Attribute Decision Making ◽  
Pulse On Time ◽  
Pulse Off Time

In this study, the effects of the process parameters on their performance characteristics of lead-induced Ti-6Al-4V alloy were investigated. Taguchi’s [Formula: see text] orthogonal array (OA) has been used to conduct the experiments. Four process parameters were considered each at three levels. Peak current, pulse-on-time, servo voltage and pulse-off-time were selected as process parameters on performance characteristics, namely, material removal rate (MRR), surface roughness (SR) and dimensional deviation (DD). A multi-attribute decision-making (MADM) technique, namely, analytic hierarchy process (AHP) and technique for order of preference by similarity to ideal solution (TOPSIS), has been used to investigate the multiple response characteristics. The weights for performance characteristics are determined by AHP. Finally, analysis of variance method has been employed effectively to bring out the influence of the process parameters associated with each performance characteristic, namely, maximization of MRR and minimization of SR and DD.

Investigation of the WEDM of Al/B4C/Gr reinforced hybrid composites using the Taguchi method and response surface methodology

2016 ◽  
Vol 23 (4) ◽  
pp. 435-445 ◽  
Author(s):  
Ali Riza Motorcu ◽  
Ergün Ekici ◽  
Abdil Kuş
Keyword(s):  
Response Surface Methodology ◽  
Taguchi Method ◽  
Response Surface ◽  
Hybrid Composites ◽  
Machining Parameters ◽  
Contribution Ratio ◽  
Control Factors ◽  
Pulse On Time ◽  
Pulse Off Time

AbstractIn this study, the effects of machining parameters on the material removal rate (MRR) and surface roughness (Ra) were investigated during the cutting of Al/B4C/Gr hybrid composites by wire electrical discharge machining (WEDM). Wire speed (WS), pulse-on time (Ton) and pulse-off time (Toff) were chosen as the control factors. The L27 (33) orthogonal array in the Taguchi method was used in the experimental design and for the determination of optimum control factors. Response surface methodology was also used to determine interactions among the control factors. Variance analysis (ANOVA) was applied in the determination of the effects of control factors on the MRR and Ra. According to the ANOVA results, the most effective parameters on MRR and Ra were wire speed with a 85.94% contribution ratio, and pulse-on-time with a 47.7% contribution ratio. The optimum levels of the control factors for MRR and Ra were determined as A3B3C3 and A1B1C2. In addition, second-order predictive models were developed for MRR and Ra; correlation coefficients (R2) were calculated as 0.992 and 0.63.

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.

Optimization of EDM Drilling Parameters for Aluminum 2024 Alloy Using Response Surface Methodology and Genetic Algorithm

2016 ◽  
Vol 706 ◽  
pp. 3-8 ◽  
Author(s):  
Setu Dave ◽  
Jay J. Vora ◽  
Nimesh Thakkar ◽  
Aditya Singh ◽  
Saurabh Srivastava ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Weight Ratio ◽  
2024 Alloy ◽  
Input Parameters ◽  
Aa 2024 ◽  
The Difference ◽  
Pulse On Time ◽  
Pulse Off Time

AA 2024 alloy is widely used as a structural material in aerospace applications. Its excellent strength to weight ratio makes it suitable for the subsequent application. The aerospace application required close tolerances and accuracy in the machined parts. Henceforth non-conventional machining processes are widely used for different machining operations such as drilling through holes. In the present study, Electrical Discharge Machining (EDM) process is used to drill through holes in 5mm thick AA 2024 alloy material. With the aim of reducing the difference between finished diameter of drilled hole and intended diameter, computational technologies were adopted for optimization. Mathematical models were developed using Response Surface methodology (RSM), and subsequently Genetic Algorithm (GA) was used to reach a set of input parameters in order to give minimum difference in diameter. Three input parameters such as current (I), Pulse on time (Ton) and Pulse off time (Toff) were selected. The ANOVA results indicated that developed models were adequate and robust. The GA based approach in conjugation with RSM was able to locate a single set of parameters which gave minimum difference in diameter. Confirmation test was again carried out and the difference between predicted and measured value was negligible.

Sign in / Sign up

Export Citation Format

Share Document