The document analyzes the effect of ultrasonic vibrations on the performance of micro-electrical discharge machining (micro-EDM) of A2 tool steel. It first discusses challenges with micro-EDM at low discharge energies and how ultrasonic vibration-assisted micro-EDM helps address these challenges by improving flushing of debris from the gap. The document then analyzes experimental data on material removal rate (MRR) and tool wear rate (TWR) under different processing conditions. Analysis of means plots and interaction plots show that MRR increases with capacitance, vibration power, and feed rate, but decreases with machining time, while TWR generally decreases with capacitance but increases with vibration power. Regression equations
Study of surface roughness for discontinuous ultrasonic vibration assisted el...eSAT Journals
Abstract The objective of this paper is to study the effects of response parameters on the performance characteristics in the Ultrasonic vibration Assisted Electric Discharge Machining (UEDM) Process. Response Surface Methodology (RSM) is used to investigate the effect of amplitude of vibration, peak current, pulse on-time, machining time and flushing pressure. To study the proposed second order polynomial model for surface roughness (SR), a Central Composite Design (CCD) is used for the estimation of the model coefficients of five factors, which are believed to influence the SR in UEDM process. Experiments are conducted on Aluminum alloy 6063 with copper electrode. The response is modeled on experimental data by using RSM. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). It is found that amplitude of vibration, peak current; pulse-on time, flushing pressure and most of their interactions have significant affect on SR. Keywords: Central Composite Design, SR, UEDM, RSM, Aluminum alloy (Al6063)
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
EDM machining is used for very hard and complex cutting of conducting materials with
higher surface finish and close dimensions. EDM process parameters are affected by both electrical
and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on
electro discharge machine with copper as cutting tool electrode. This paper presents the effect of
control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge
Machine. In this paper both the electrical factors and non electrical factors has been focused which
governs MRR and EWR. Paper is based on Design of experiment and optimization of EDM process
parameters. The technique used is Taguchi technique which is a statistical decision making tool helps
in minimizing the number of experiments and the error associated with it. The research showed that
the Pulse off time, Current has significant effect on material removal rate and electrode wear rate
respectively
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
Study of surface roughness for discontinuous ultrasonic vibration assisted el...eSAT Journals
Abstract The objective of this paper is to study the effects of response parameters on the performance characteristics in the Ultrasonic vibration Assisted Electric Discharge Machining (UEDM) Process. Response Surface Methodology (RSM) is used to investigate the effect of amplitude of vibration, peak current, pulse on-time, machining time and flushing pressure. To study the proposed second order polynomial model for surface roughness (SR), a Central Composite Design (CCD) is used for the estimation of the model coefficients of five factors, which are believed to influence the SR in UEDM process. Experiments are conducted on Aluminum alloy 6063 with copper electrode. The response is modeled on experimental data by using RSM. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). It is found that amplitude of vibration, peak current; pulse-on time, flushing pressure and most of their interactions have significant affect on SR. Keywords: Central Composite Design, SR, UEDM, RSM, Aluminum alloy (Al6063)
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
EDM machining is used for very hard and complex cutting of conducting materials with
higher surface finish and close dimensions. EDM process parameters are affected by both electrical
and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on
electro discharge machine with copper as cutting tool electrode. This paper presents the effect of
control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge
Machine. In this paper both the electrical factors and non electrical factors has been focused which
governs MRR and EWR. Paper is based on Design of experiment and optimization of EDM process
parameters. The technique used is Taguchi technique which is a statistical decision making tool helps
in minimizing the number of experiments and the error associated with it. The research showed that
the Pulse off time, Current has significant effect on material removal rate and electrode wear rate
respectively
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Optimization of edm for mrr of inconel 600 using taguchi methodsushil Choudhary
Electrical discharge machining (EDM) process is convert electrical energy into heat energy between the work piece and tool electrode in the presence of dielectric fluid like, EDM oil, to process conductive difficult-to-machine materials. EDM process is has been applicable in the machining of hard, brittle and all kinds of electric conductive materials. This process widely used for produces die making, mould making, complex shapes, deep holes and other geometrical shapes as per desire. Inconel 600 super alloy materials widely used in various types of industries such as: aerospace, aircraft, nuclear, food processing, pulp manufacturing, automobiles industry etc. In this study, investigations on the effect of process parameters on machining of Inconel 600 super alloy material. Tungsten carbide material used as tool electrode and EDM oil used as dielectric fluid. The effects of input process parameters such as pulse-on-time, peak current and gap voltage on performance measure material removal rate was investigated using Taguchi method. MRR is lineally increases with the increase in peak current during the EDM process. MRR is increases with the increase in gap voltage. Initially MRR increases with increase in pulse on time then decreases with the increase of pulse on time.
Optimization of machining parameters of Electric Discharge Machining for 202 ...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 34 (=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9μs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13μs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1μin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
The term steel is used for many different alloys of iron. All steels cover small amounts of carbon and manganese. There do exist many types of steels which are(among others) plain carbon steel, stainless steel, alloysteel and tool steel. Carbon steel is the most extensively used kind of steel. The properties of carbon steel depend mainly on the amount of carbon it contains. Maximum carbon steel has a carbon content of less than 1%. Carbon steel is made into an extensive range of products, including structural beams, car bodies. In fact, there are 3 types of plain carbon steel namely low carbon steel, medium carbon steel, high carbon steel. It is good to exact that plain carbon steel is a type of steel having a maximum carbon content of 1.5% along with small percentages of silica, Sulphur, phosphorus and manganese. EN 1010 is a lowest amount of carbonalloy steel alloy with carbon content of 0.10%. Machineability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is usually used for rivets and bolts, construction and automotive applications such as pans, nails and transmission cover. The objective of paper is to study the effect of process parameters namely pulse on time, pulse off time, peak current and servo voltage on surface roughness(SR).The effect of process parameters on productivity and accuracy facts is material dependent. To study parametric effect on Surface Roughness a Central Composite design approach of response surface methodology (RSM) is used to plan and study the experiments. The mathematical relationships between WEDM input process parameters and response parameter namely surface roughness is established to determine optimal values of surface roughness mathematically and graphically.The Analysis of variance (ANOVA) is performed to find statistically significant process parameters. Interaction effects of process parameters on surface roughness are analysed using statistical and graphical representations.
DESIGN OF INTELLIGENT CONTROL SYSTEM USING ACOUSTIC PARAMETERS FOR GRINDING M...cscpconf
This paper utilizes acoustic parameters such as FS,NC, N, P, INC, FL, FH, W for acoustic signals S of different running conditions of a ballmill to deriveout the acoustic signatures and
hence control signals, which is to be used for designing the control systems of the mill. The parameters FS, NC, N, P, INC, FL, FH and W are represented by sample rate in Hz, number of
cepstral coefficients, length of frame in samples, number of filters in filter bank, frame increment, low end of the lowest filter, high end of highest filter and the window over which the analysis is to be performed respectively. The work establishes an
appropriate theoretical background that helps to predict dynamic breakage characteristics with respect to particle size
distribution of materials, adequately supported by experimental data. The signatures of different running conditions of grinding mill have been extracted from the captured signal in time frame
these have been used as feedback signal to monitor the grinding operation. Condenser based microphones have been used for capturing acoustic signals in time domain directly in
computers and stored for further analysis. Matlab R2010b has been used for different analysis of the experiment. On analyzing the signatures, it has been observed whether the fines are
produced progressively to attain the desired size range or the mill producing undesired products. Thus, the approach has been used in this paper has the ability to arrive in the stage of
optimum grinding by tuning parameters of the mill in real time, and also it can prevent the mill to enter into an erroneous state. Moreover, on study it has found that the present scheme can be
used more accurately in comparison to the earlier work of the author. This paper presents an implementation scheme to use acoustic signal as the control signal to regulate the operation of
a grinding mill.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Peristaltic flow of blood through coaxial vertical channel with effect of mag...ijmech
The present paper investigates the effects of peristaltic flow of blood through coaxial vertical channel with
effect of magnetic field: blood flow study.The effects of various physical parameters on axial velocity and
pressure gradient have been computed numerically. It is observed that the maximum velocity increases
with increase in Magnetic field (M) even though for phase shiptııııı/ 4 for all the two cases
= - 0.5,
= -1. However, opposite effects are noticed for
= 0.5,
= 1.
Dynamic aerodynamic structural coupling numerical simulation on the flexible ...ijmech
Most biological flyers undergo orderly deformation in flight, and the deformations of wings lead to complex fluid-structure interactions. In this paper, an aerodynamic-structural coupling method of flapping wing is developed based on ANSYS to simulate the flapping of flexible wing.
Firstly, a three-dimensional model of the cicada’s wing is established. Then, numerical simulation method of unsteady flow field and structure calculation method of nonlinear large deformation are studied basing on Fluent module and Transient Structural module in ANSYS,
the examples are used to prove the validity of the method. Finally, Fluent module and Transient Structural module are connected through the System Coupling module to make a two-way fluidstructure Coupling computational framework. Comparing with the rigid wing of a cicada, the
coupling results of the flexible wing shows that the flexible deformation can increase the aerodynamic performances of flapping flight.
ANALYSIS OF ENERGY CONSERVATION OF AN INSTITUTIONAL BUILDING USING DESIGN BUI...ijmech
Buildings contribute impact on CO2 emission and energy consumption. Electric energy
consumption in buildings is about 40% of the total energy consumption of India. In this work building
simulation technology is used to evaluate a variety of envelope thermal characteristics and low carbon
technology in an integrated manner at the early design stage itself to assist the delivering of sustainable
green buildings with a high rating of performance and energy consumption. Building simulation enables
designer to identify the key energy loads, test their strategies and compare permutation of design strategy
in order to optimize the energy consumption.
Design Builder (DB) software is used to carry out a series of sensitivity analysis on set of design
parameters, with an aim to achieve a comfortable and energy efficient building. Several parametric studies
have been conducted to enable building designers to carry out analysis of energy efficient building model
related to building orientation, construction, air infiltration, natural ventilation, window type, openings,
and lighting. To calculate the energy saving, basic condition of building model is compared with Energy
Conservation Building Code (ECBC) building model. Consider basic condition of building is case A and
condition of building according to ECBC is case B.
Investigation on Optimization of Machining Parameters in Wire EDM using Taguc...ijsrd.com
In this paper, the parameters used in the cutting of Cemented Tungsten Carbide using wire electrical discharge machining (WEDM) with a Brass electrode was optimized using Taguchi method. Taguchi method is used to formulate the experimental layout and to analyze the effect of each parameter on the machining characteristics. Also it is used to predict the optimal choice for each parameter such as peak current, voltage, and pulse duration and interval time. It was found that these parameters have significant influence on machining characteristics such as Metal Removal Rate (MRR) and Surface Roughness (SR). The result of the work reveals that, the peak current significantly affects the Surface Roughness (SR) and the pulse duration mainly affects the Metal Removal Rate (MRR).
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Optimization of edm for mrr of inconel 600 using taguchi methodsushil Choudhary
Electrical discharge machining (EDM) process is convert electrical energy into heat energy between the work piece and tool electrode in the presence of dielectric fluid like, EDM oil, to process conductive difficult-to-machine materials. EDM process is has been applicable in the machining of hard, brittle and all kinds of electric conductive materials. This process widely used for produces die making, mould making, complex shapes, deep holes and other geometrical shapes as per desire. Inconel 600 super alloy materials widely used in various types of industries such as: aerospace, aircraft, nuclear, food processing, pulp manufacturing, automobiles industry etc. In this study, investigations on the effect of process parameters on machining of Inconel 600 super alloy material. Tungsten carbide material used as tool electrode and EDM oil used as dielectric fluid. The effects of input process parameters such as pulse-on-time, peak current and gap voltage on performance measure material removal rate was investigated using Taguchi method. MRR is lineally increases with the increase in peak current during the EDM process. MRR is increases with the increase in gap voltage. Initially MRR increases with increase in pulse on time then decreases with the increase of pulse on time.
Optimization of machining parameters of Electric Discharge Machining for 202 ...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 34 (=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9μs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13μs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1μin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
Improvement of Surface Roughness of Nickel Alloy Specimen by Removing Recast ...IJMER
Abstract: In this investigation, experimental work and computational work are combined to obtain improvement in the surface roughness of nickel alloy specimen, the machining is carried out by means of CNC wire electric discharge machining (WEDM). Brass wire is used as the tool electrode and nickel alloy (Inconel600) is used as the work piece material. The machining parameters such as Pulse-On time (Ton), Pulse-Off time (Toff), Peak Current (Ip), and Bed speed are considered as input parameters for this project. Surface roughness and Recast layer are considered the output parameters. The experiments
with the pre-planned set of input parameters are designed based on Taguchi’s orthogonal array. The surface roughness is measured using stylus type roughness tester and the thickness of the Recast layer is measured using Scanning Electron Microscope (SEM). The results obtained from the experiments are fed to the Minitab software and optimum input parameters for the desired output parameters are identified. The software uses the concept of analysis of variance (ANOVA) and indicates the nature of effect of input parameters on the output parameters and confirmation is done by validation
experiments. Once the recast layer thickness is obtained Chemical Etching and abrasive blasting is performed in order to remove the recast layer and again the surface roughness is measured by using stylus type roughness tester. Finally from the obtained results it was found that there was significant improvement in the Surface roughness of the nickel alloy material. In addition using regression analysis this work is stimulated by computational method and the results are obtained
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
The term steel is used for many different alloys of iron. All steels cover small amounts of carbon and manganese. There do exist many types of steels which are(among others) plain carbon steel, stainless steel, alloysteel and tool steel. Carbon steel is the most extensively used kind of steel. The properties of carbon steel depend mainly on the amount of carbon it contains. Maximum carbon steel has a carbon content of less than 1%. Carbon steel is made into an extensive range of products, including structural beams, car bodies. In fact, there are 3 types of plain carbon steel namely low carbon steel, medium carbon steel, high carbon steel. It is good to exact that plain carbon steel is a type of steel having a maximum carbon content of 1.5% along with small percentages of silica, Sulphur, phosphorus and manganese. EN 1010 is a lowest amount of carbonalloy steel alloy with carbon content of 0.10%. Machineability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is usually used for rivets and bolts, construction and automotive applications such as pans, nails and transmission cover. The objective of paper is to study the effect of process parameters namely pulse on time, pulse off time, peak current and servo voltage on surface roughness(SR).The effect of process parameters on productivity and accuracy facts is material dependent. To study parametric effect on Surface Roughness a Central Composite design approach of response surface methodology (RSM) is used to plan and study the experiments. The mathematical relationships between WEDM input process parameters and response parameter namely surface roughness is established to determine optimal values of surface roughness mathematically and graphically.The Analysis of variance (ANOVA) is performed to find statistically significant process parameters. Interaction effects of process parameters on surface roughness are analysed using statistical and graphical representations.
DESIGN OF INTELLIGENT CONTROL SYSTEM USING ACOUSTIC PARAMETERS FOR GRINDING M...cscpconf
This paper utilizes acoustic parameters such as FS,NC, N, P, INC, FL, FH, W for acoustic signals S of different running conditions of a ballmill to deriveout the acoustic signatures and
hence control signals, which is to be used for designing the control systems of the mill. The parameters FS, NC, N, P, INC, FL, FH and W are represented by sample rate in Hz, number of
cepstral coefficients, length of frame in samples, number of filters in filter bank, frame increment, low end of the lowest filter, high end of highest filter and the window over which the analysis is to be performed respectively. The work establishes an
appropriate theoretical background that helps to predict dynamic breakage characteristics with respect to particle size
distribution of materials, adequately supported by experimental data. The signatures of different running conditions of grinding mill have been extracted from the captured signal in time frame
these have been used as feedback signal to monitor the grinding operation. Condenser based microphones have been used for capturing acoustic signals in time domain directly in
computers and stored for further analysis. Matlab R2010b has been used for different analysis of the experiment. On analyzing the signatures, it has been observed whether the fines are
produced progressively to attain the desired size range or the mill producing undesired products. Thus, the approach has been used in this paper has the ability to arrive in the stage of
optimum grinding by tuning parameters of the mill in real time, and also it can prevent the mill to enter into an erroneous state. Moreover, on study it has found that the present scheme can be
used more accurately in comparison to the earlier work of the author. This paper presents an implementation scheme to use acoustic signal as the control signal to regulate the operation of
a grinding mill.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Peristaltic flow of blood through coaxial vertical channel with effect of mag...ijmech
The present paper investigates the effects of peristaltic flow of blood through coaxial vertical channel with
effect of magnetic field: blood flow study.The effects of various physical parameters on axial velocity and
pressure gradient have been computed numerically. It is observed that the maximum velocity increases
with increase in Magnetic field (M) even though for phase shiptııııı/ 4 for all the two cases
= - 0.5,
= -1. However, opposite effects are noticed for
= 0.5,
= 1.
Dynamic aerodynamic structural coupling numerical simulation on the flexible ...ijmech
Most biological flyers undergo orderly deformation in flight, and the deformations of wings lead to complex fluid-structure interactions. In this paper, an aerodynamic-structural coupling method of flapping wing is developed based on ANSYS to simulate the flapping of flexible wing.
Firstly, a three-dimensional model of the cicada’s wing is established. Then, numerical simulation method of unsteady flow field and structure calculation method of nonlinear large deformation are studied basing on Fluent module and Transient Structural module in ANSYS,
the examples are used to prove the validity of the method. Finally, Fluent module and Transient Structural module are connected through the System Coupling module to make a two-way fluidstructure Coupling computational framework. Comparing with the rigid wing of a cicada, the
coupling results of the flexible wing shows that the flexible deformation can increase the aerodynamic performances of flapping flight.
ANALYSIS OF ENERGY CONSERVATION OF AN INSTITUTIONAL BUILDING USING DESIGN BUI...ijmech
Buildings contribute impact on CO2 emission and energy consumption. Electric energy
consumption in buildings is about 40% of the total energy consumption of India. In this work building
simulation technology is used to evaluate a variety of envelope thermal characteristics and low carbon
technology in an integrated manner at the early design stage itself to assist the delivering of sustainable
green buildings with a high rating of performance and energy consumption. Building simulation enables
designer to identify the key energy loads, test their strategies and compare permutation of design strategy
in order to optimize the energy consumption.
Design Builder (DB) software is used to carry out a series of sensitivity analysis on set of design
parameters, with an aim to achieve a comfortable and energy efficient building. Several parametric studies
have been conducted to enable building designers to carry out analysis of energy efficient building model
related to building orientation, construction, air infiltration, natural ventilation, window type, openings,
and lighting. To calculate the energy saving, basic condition of building model is compared with Energy
Conservation Building Code (ECBC) building model. Consider basic condition of building is case A and
condition of building according to ECBC is case B.
Application of value stream mapping tool to reduce wastes in bearing industryijmech
In today’s highly competitive business environment, companies require improvement in Production Lead
Times, costs and customer service levels to survive. Because of this, companies have become more
customers focused. The result is that companies have been putting in significant effort to improve their
efficiency.
This paper present the practical application of Value Stream Mapping (VSM) tool implement in a bearing
industry. A value stream is an assortment of all actions (value added as well as non-value added) that are
required to bring a product through the essential flows, starting with raw material and ending with the
customer. For drawing current state value stream mapping, all relevant data has been collected and analyzed. Then analysis of current state map has been done for identifying non-value adding activities, in
other words waste and suggestions on how to remove or reduce different wastes. From the results achieved
by current VSM, it was observable that the two processes Annealing and CNC Machining have higher cycle
time and WIP. In order to increase their capacity, their cycle should be reduced.
By implementing some lean principles and changes in the production line, the future state map was created and the reduction the different types of wastes reduced. The total processing time was reduced from 409
seconds to 344 seconds.
APPLICATION OF TAGUCHI METHOD FOR PARAMETRIC STUDIES OF A FUNNEL SHAPED STRUC...ijmech
In this paper, attempt has been made to minimize sound reflection from the wall by using Taguchi’s method and to find optimal structure for the suggested test-section inside the cavitation tunnel. The suggested structure which was added to the test-section is funnel-shaped with a performance like a check valve. In order to obtain approximate values of five independent parameters, three levels were taken into account for each parameter. By combining parameters of different levels, 27 tests were designed using Taguchi’s method and Minitab Software. Different acoustic analyses were conducted in COMSOL Multiphysics software, and defined parameter of general reflection coefficient was obtained for 21 observer points. Applying the general reflection coefficients to Minitab Software and drawing the SNR graph, approximate values of the parameters were obtained. However, these values did not produce enough accuracy to design the optimal structure. For this reason, five levels around optimal values, obtained from the previous analysis, were considered for each parameter. Same steps were repeated again for the parameters at five
levels and optimal values were obtained. Optimal structure was modelled and analyzed. Consequently, appropriate defined parameters of general and local reflection coefficients were extracted which represented an optimal structure for the intended test section.
Gas foil bearing analysis and the effect of bump foil thickness on its perfor...ijmech
Gas foil bearings (GFBs) satisfy many of the requirements noted for novel oil-free turbomachinery.However, GFBs have a limited load carrying capacity. This paper presents a numerical model in order to assess the performance characteristics of gas foil bearings. The finite difference scheme has been used to discretize the governing Reynolds equation and the pressure is calculated by solving non-linear matrix equation using Newton-Raphson technique. The static performance analysis has been carried out. The computational analysis have been compared with the experimental and theoretical results available in the literature and the effects of bump foil thickness, number of bumps and bump compliance coefficient on the load carrying capacity at different rotor speed have been investigated. The results of the study show that too thin bump foil thickness may lead to a significant decrease in the load capacity. However for accurate predictions of the foil bearing performances, more details foil structure of 1D and 2D finite element model
should be considered.
ANALYSIS OF EMISSION CHARACTERISTIC OF NM-DIESEL BLEND ON VCR DIESEL ENGINEijmech
The consumption of fuel is increasing resulting in pollution of environment with smoke and NOx due to the
development in automobile and power sector. These emission contents smoke and NOx can be reduced by
adding additives with diesel fuel. As these additives are very costly and hence becomes unviable. These
additives decrease the performance of combustion.
Oxygenated compounds are most widely used among additives. The reason for this is the participation of
their oxygen in reactions leading to better combustion and hence lowering the emission contents the
molecular structure of the oxygen contents of additives directly influence on smoke reduction and the
oxygen concentration of the fuel flame also effects the emission specially Nitro paraffin compound
additives have high oxygen contents is then molecular structure. So we considered as oxygenated
additives.
We have used nitro methane (NM) (2%) as an additives with diesel while analyzing the emission
characteristic on VCR Engine
Suppressing undesired vibration of 3 r robot arms using impact dampersijmech
The behavior of a vibration system suppressed with an impact damper is investigated, where the impact
damper is simplified as a combination of spring and viscous damping. The analytical answer for the contact duration is developed using iteration perturbation technique. Iteration perturbation is a new analytical technique which can solve strongly nonlinear equations. In the presented work an impact damper is used to reduce the undesired vibration of an industrial robot arm. For this reason a 3R robot is equipped with a simple model of a single unit impact damper which is constructed using spring, mass and viscous damper. The output forces of robot with and without impact damper are compared and effects of using the impact damper on correct application of the robot are shown
STUDY OF RECAST LAYERS AND SURFACE ROUGHNESS ON AL-7075 METAL MATRIX COMPOSIT...ijmech
Demand for low weight to strength ratio for exclusive application in automobile and aerospace components created scope for advance studies on Metal Matrix Composites (MMCs). However, machining of MMCs challenges for conventional machining processes due to uneven hardness, matrix of composites and undesired tool life. Electric Discharge Machining (EDM) is one of the unconventional material removal process, which offers alternatives for machining of MMCs because, being a non-contact process it can be machine excessive harder material, intricate shape with better surface finish and tool life. The evolved heat during EDM process and subsequent flushing of machined debris and rapidly resolidified layer is formed by the re-solidification of residual molten material on the machined surface during the EDM process leaves behind recast layers which is extremely hard and brittle. In the presents study optimization of process parameters to minimize the surface roughness of the rapidly resolidified layer of Al 7075 MMC while
machining using EDM process is carried out using the Taguchi tequniues. The gap current, pulse on-time and pulse off-time were considered as process parameters. The formation of resolidified layers is investigated in terms of the surface roughness as response variables inside the hole and near the hole while EDM drilling.
PREDICTION OF REPAIR & MAINTENANCE COSTS OF DIESEL ENGINEijmech
Diesel engine is widely use for different applications, the failure frequency of diesel engine is more increase to increase the age & use of engine in order to take decision to replacement of engine on the basis of Repair & Maintenance cost (R&M) & predication of future Repair & Maintenance costs of diesel engine used in Borewell compressor. Present case study discusses prediction of accumulated R&M costs (Y) of Diesel engine against usage in hours (X). Recorded data from the company service station is used to determine regression models for predicting total R&M costs based on total usage hours. The statistical results of the study indicates that in order to predict total R&M costs is more useful for replacement
decisions than annual charge.
DESIGN AND FABRICATION OF AN INDIAN ARMY VEHICLE (A CAR FOR THE CIVIL AREA WA...ijmech
The function of this car is to provide convenience to the soldiers in the civil area warzone. Unlike other
army vehicles, this car has broad tires which works well on the road. The car has four forward gears &
four reverse gears. So after firing on the target the driver has no need to waste the time in turning the
vehicle. As the differential is fixed in all other vehicles but in this project we placed a modified moving
differential. Which changes its position between the forward and the reverse gear drive shafts. Hence
provide convenience to the gear shifting. The car has chassis less construction. i.e., the body has directly
mounted on the frame of the car with the help of fasteners. The car body is made up of fiberglass, we used
the approach of clay modeling in the designing of the molds and the virtual design of the car body is
designed under Catia V5. The parts of the car has been taken from the junkyard, the flushed cleaned,
greased or oiled , fitted , modified if needed, tested and then painted and finally assembled in the vehicle.
NUMERICAL INVESTIGATION OF NATURAL CONVECTION HEAT TRANSFERFROM SQUARE CYLIND...ijmech
The enhancement of natural convection heat transfer using nanofluids from horizontal square cylinder
placed in a square enclosure is investigated numerically. Water-based Cu is used as the working nanofluid.
The investigation covered a range of Rayleigh numbers of 104
- 106
, nanoparticles volume fraction of
(0<ϕ≤0.2), enclosure width to cylinder height ratio, W/H of 2.5. The investigation includes the solution of
the governing equations in the Vorticity-Stream function space with the aid of a body fitted coordinate
system. Algebraic grid generation is used in the initial transformations, followed by an elliptic
transformation to complete the grid generation to computational domain. The resulting discretized system
of equations is solved using an ADI method. The built code is validated and the results showed an increase
in average Nusselt number with increasing the volume fraction of the nanoparticles for the whole range of
Rayleigh number. The isotherms are nearly similar when the volume fraction of nanoparticles is increased
from 0 to 0.2 for each Rayleigh number but a change in the streamlines is observed.
A BENCHMARK MODEL FOR INTERNAL ASSESSMENT OF INDUSTRY USING FUZZY TOPSIS APPR...ijmech
Internal assessment is one of the most important factor of an industry, needs appropriate improvement
planning between the departments with development of Benchmark model among them. The proposed study
applies Fuzzy Technique for Order Preference by Similarity to Ideal Solution to rank different alternatives.
The preliminary results indicate that the proposed model is capable of determining appropriate
competition between departments which are Human Resource, Finance, Production, Quality Assurance. To
remove the subjectivity, the linguistic data about the attributes is converted into a crisp score by using
fuzzy numbers and then the different alternatives are evaluated based on attributes by TOPSIS approach to
find the best alternative according to the industry’s requirement. Thus the endeavor has been made by the
authors to give a simple model for the evaluation of internal assessment of an industry
PARAMETRIC DESIGN ANALYSIS AND FEA SIMULATION OF A CHISEL PLOW FOR AN AGRICUL...ijmech
CAD Software for the structural analysis is basically used for the application of CAD/CAM in design
optimization of tillage tools, which is based on the simulation method and Finite Element Method. The
various components of the tillage tools are simulated with help of actual field performance rating
parameters which are prepared by solid models along with actual boundary conditions. The planned work
outcomes of sufficient tolerance in varying the working parameters of Chisel Plow sections for ejecting the
extra weight in a solid section and also to increase the weight of plow for a consistent potency.
In this paper parametric study of two different kinds of Chisel Plow for an agriculture use in designing
from stress, strain, deformation and fatigue analysis has done. One is Old Chisel Plow & another is New
Generation Chisel Plow. The old working model of Chisel Plow is compared with new design parameters
with change of its geometry for the maximum weed exclusion efficiency by showing its realistic results from
the actual field performance.
OPTIMIZATION AND FATIGUE ANALYSISOF A CRANE HOOK USING FINITE ELEMENT METHODijmech
Stress analysis plays an important role in the design of structures like crane hook under loading conditions.
Crane hook is a reliable lifting component being used in industries. Structure failure of crane hook occurs
because of the stress induced due to repetitive loading and unloading conditions. In this study, solid
modeling of crane hook having trapezoidal cross-section referring to one of its existing design is done
using SOLIDWORKS. Further, analyses are carried out in ANSYS Workbench and nCode DesignLife. The
lengths of two parallel sides of the cross-section of crane hook are varied and different candidates are
obtained for loading capacity of 30 ton on the basis of Mass, total Displacement and Von-Mises stress.This
is done to reduce weight and balance economy. Further, out of these candidates, best candidates are
considered and fatigue analysis is performed on these candidates.
RENEWABLE ENERGY ALTERNATIVE FOR WASTEWATER TREATMENT PLANTS IN TRINIDAD - A ...ijmech
The feasibility of using solar photovoltaic (PV) as an alternative to power a waste water treatment plant
(WWTP) in Trinidad was investigated. The site data and power consumption of the Orangefield WWTP
was used to size a PV system with and without grid tied and tracking and non-tracking options. Present day
costing was determined and a simple payback period for Trinidad and Tobago was calculated. The
analysis indicated a minimum and maximum payback period of 27 years and 97.4 years, respectively.
Therefore, in Trinidad and Tobago, even the most cost effective PV system was not financially feasible. A
comparative payback period for neighbouring countries of Barbados and St. Vincent, with three times
higher power cost than Trinidad and Tobago, indicated that solar power is more attractive and feasible
with a minimum and maximum payback period of 9.1 and 8.6 years and 32.8 and 31.2 years, respectively
NUMERICAL STUDY OF FLUID FLOW AROUND A DIVER HELPERijmech
Having access to high speed diving without the use of mechanical science and discovery centers have been
considered. Production of simple, yet effective tool to reduce energy consumption and associated diver is
very valuable. Assistant diver device that works with human muscle power, includes a pair of ballets. This
system reduces the energy required to dive to less than half as the speed increases to 2 to 5 knot. Using
numerical methods can answer a lot of questions and a simulation of the dynamic behavior of the device. In
this article, modeling of fluid flow around the Diver helper of FLUENT software and using Dynamic Mesh
have been done.
Flow lines show an increase in the angle of the fins and causes development of vortices behind them.
Pressure Cantor can also be used in the analysis of the fins. The drag coefficient ballet based on the device
at various angles in a period is reported in charts.
OCCUPATIONAL HEALTH AND ERGONOMIC INTERVENTION IN INDIAN SMALL SCALE INDUSTRI...ijmech
The small scale industries (SSIs) play very important role in the Indian economy. SSIs contribute in terms
of industrial production, export, employment and creation of an entrepreneurial base for the country. In
most of the SSIs in India, either traditionally designed tools are used or manual work is performed. Long
hours work with traditionally designed tools and un-ergonomic work places can cause musculoskeletal
disorders (MSDs) and other occupational health problems among workers. Workers well-being is highly
associated with the productivity and cost benefits of small scale industries. This review paper aims to
identify various MSDs and occupational health problems among workers in SSIs. The effects of ergonomic
interventions for improved occupational healthas well as productivity enhancement and cost benefits of
SSIs are also reviewed in paper.
INFLUENCE OF PROCESS PARAMETERS ON SURFACE ROUGHNESS AND MATERIAL REMOVAL RAT...ijmech
Optimization of machining parameters is very valuable to maintain the accuracy of the components and
obtain cost effective Machining.MRR (material removal rate) and surface roughness is playing primary
role in manufacturing using contemporary CNC (computer numerical controlled) machines, in the case of
mass manufacturing. In present study experimental and work is done for optimization of process
parameters. In experimental work total 32 experiments are designed according DOE method “Mixed
taguchi”. Three factors are selected for experimental work. Depth of cut, speed and feed rate is selected
factors for experimental work. All experiments are carried out in CIPET, Jaipur. Two responses are find
out in this work and are following: first one is material removal rate (MRR) and second response is surface
roughness (Ra) measurement. An artificial neural network is ‘Feed Forward Back Propagation’ type
model of developing the analysis and prediction of surface roughness and MRR with relationship between
all input process parameters
EFFECT OF EDM PARAMETERS IN OBTAINING MAXIMUM MRR AND MINIMUM EWR BY MACHININ...IAEME Publication
EDM machining is used for very hard and complex cutting of conducting materials with higher surface finish and close dimensions. EDM process parameters are affected by both electrical and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on electro discharge machine with copper as cutting tool electrode. This paper presents the effect of control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge Machine.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected tht
rough rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Micron range complex structure in micro electrochemical machining- a revieweSAT Journals
Abstract
The major problem in the micro-manufacturing is concerned with achieving the good dimensional accurate products with the better surface finish, high MRR, no tool wear, absence of stress and no heat-affected zone. Micro-machining proved itself as a promising solution of this major problem. In recent days, industries are regularly looking for fabricating the micro-components which can be able to perform their complex functions in the sensitive areas of electronics, automotive, biomedical and optics. Now a day for miniature components micro-machining plays a very important role, its techniques are excellent to machine any complex shapes with good accuracy and bright surface finish. Material with any value of the hardness can be machined easily with all the offered advantages of micro-machining in the electrochemical micro-machining process (EMM). In this article; review of different methodologies and effect of machining parameters were studied along with different electrolytes; which plays a significant role in electro chemical micro-machining. The objective of this study is to know about the optimum micro-machining parameters for the EMM process and it is also much important to find out the research gap through the different studies. In this study, it has been found out MRR and overcut are depends upon the voltage, electrolyte concentration, IEG, pulse ON/OFF time, pulse duration, pulse frequency, RPM of the tool and flow rate of electrolyte. The proper selections of parameters in EMM are essentials for achieving the overall improvement in the micro-machining operation.
Micron range complex structure in micro electrochemical machining- a revieweSAT Journals
Abstract
The major problem in the micro-manufacturing is concerned with achieving the good dimensional accurate products with the better surface finish, high MRR, no tool wear, absence of stress and no heat-affected zone. Micro-machining proved itself as a promising solution of this major problem. In recent days, industries are regularly looking for fabricating the micro-components which can be able to perform their complex functions in the sensitive areas of electronics, automotive, biomedical and optics. Now a day for miniature components micro-machining plays a very important role, its techniques are excellent to machine any complex shapes with good accuracy and bright surface finish. Material with any value of the hardness can be machined easily with all the offered advantages of micro-machining in the electrochemical micro-machining process (EMM). In this article; review of different methodologies and effect of machining parameters were studied along with different electrolytes; which plays a significant role in electro chemical micro-machining. The objective of this study is to know about the optimum micro-machining parameters for the EMM process and it is also much important to find out the research gap through the different studies. In this study, it has been found out MRR and overcut are depends upon the voltage, electrolyte concentration, IEG, pulse ON/OFF time, pulse duration, pulse frequency, RPM of the tool and flow rate of electrolyte. The proper selections of parameters in EMM are essentials for achieving the overall improvement in the micro-machining operation.
Keywords: Micro-Manufacturing, Micro-Machining, Electrochemical Machining (ECM), Electrochemical Micro-Machining (EMM).
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
Electro Discharge Machining (EDM) is a
non-traditional machining process, based on thermo electric
energy between the work piece and electrode. In this process,
the material removal is occurred electro thermally by a series
of successive discrete discharges between electrode and the
work piece. Electro Discharge Machine which has the ability to
machine hard, difficult to machine material and parts with
internal complex shape by using precisely controlled sparks
that occurs between electrode and work piece in the presence
of dielectric fluid. This spark removes material from both work
piece and electrode. Material Removal Rate (MRR) is of
crucial importance in this process. In this research experiment
has been done along with Copper and Graphite tool material as
well as Mild Steel and Aluminium material has been used as
work piece. Three major Control Parameters named as
Electrode Speed (V), Current (I) and Depth of Cut (h) are
considered to determine their influence on MRR. In this
experiment three levels of each parameter has been taken and
an analysis has been made to find out the influence of control
parameters on MRR using S/N Ratio and ANOVA Analysis
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9µs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13µs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1µin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
MULTI OBJECTIVE OPTIMIZATION OF NEAR-DRY EDM PROCESS USING RESPONSE SURFACE M...IAEME Publication
The correct selection of manufacturing technique is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). It is capable of machining geometrically complex or hard
material components, which are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries.
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GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using Deplo...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
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ANALYSIS OF THE EFFECT OF ULTRASONIC VIBRATIONS ON THE PERFORMANCE OF MICROELECTRICAL DISCHARGE MACHINING OF A2 TOOL STEEL
1. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
DOI: 10.14810/ijmech.2016.5301 1
ANALYSIS OF THE EFFECT OF ULTRASONIC
VIBRATIONS ON THE PERFORMANCE OF MICRO-
ELECTRICAL DISCHARGE MACHINING OF A2 TOOL
STEEL
Govindan Puthumana
Postdoctoral Researcher
Department of Mechanical Engineering, Technical University of Denmark, Lyngby.
ABSTRACT:
The application of ultrasonic vibrations to a workpiece or tool is a novel hybrid approach in micro-
electrical discharge machining. The advantages of this method include effective flushing out of debris,
higher machining efficiency and lesser short-circuits during machining. This paper presents a systematic
analysis of the influence of kinetic effects of the ultrasonic vibrations on the material removal rate (MRR)
and tool electrode wear rate (TWR). The tool wear ratio was estimated for the process at all processing
conditions. The maximum variation in tool wear ratio is observed to be 82%. Therefore, MRR and TWR
were independently analyzed by using three scientific tools: i) AOM plots, ii) interaction plots and iii)
three-dimensional scatter plots. The increase in MRR is 47% corresponding to an increase in the maximum
power of vibrations by 30%. The ultrasonic vibrations are found to be very effective at higher machining
depths for achieving stable machining conditions. Regression equations were developed for MRR and TWR
with capacitance, ultrasonic vibration factor, feed rate and machining time.
KEYWORDS:
Micro-electrical discharge machining, Ultrasonic vibration, hybrid machining, Material removal, tool
electrode wear, AOM.
1. INTRODUCTION
In micro-electrical discharge machining, each electrical discharge generates thermal energy
causing melting and evaporation of material, without any contact between the tool electrode and
the workpiece. The properties of the material such as toughness, hardness and brittleness has no
effect on the material removal mechanism. Because of the capability to generate complex micro-
features, the micro-EDM process has been extensively used in tool and mould making industry.
Furthermore, the spark machining methods have been applied in several fields related to
micromachining and prototyping [1]. The demand for micro-parts and components are increasing
at a very rapid rate, and thus, the micro-EDM technology is being modified to achieve efficient
machining at micro-scale [2]. One of the techniques to minimize the removal is to reduce the
discharge energy. The discharge energy of the micro-EDM process is less than 100 µJ in a spark,
and by reducing the current and pulse-on time parameters to 1 A and 0.2 µs respectively, a
minimum discharge energy of 5 µJ is achievable under normal processing conditions [3]. There
are few challenges to operate micro-EDM at low discharge energies; they are: 1) unstable
2. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
2
machining conditions in the inter-electrode gap due to higher number of short-circuits, 2) lower
productivity and 3) geometrical inaccuracy in the features generated, and 4) poor surface finish.
The number of short-circuits, arcing and abnormal discharges increases as the depth of the feature
machined increases, and is a problem when the aspect ratio of the feature is high [4]. Researchers
have identified concentration of debris in the spark gap as one of the key reasons, and have
proposed various measures to improve the flushing out of debris and thereby to enhance the
performance of the micro-EDM process, such as external jet flushing, sucking pump flushing,
flushing by lifting and rotational flushing. However, due to small size of the operating region
(less than 50 µm) and discharge gap (of the order of 10 µm), these conventional methods are
mostly ineffective. In order to attain stable machining conditions, it is therefore necessary to use
new approaches.
In ultrasonic vibration-assisted micro-EDM, a high frequency vibration of the order of 30-60 kHz
is introduced either to the tool or to the workpiece, in the range of amplitudes of 5 to 10 µm [5].
The application of vibration causes significant improvements in the circulation of the dielectric
and improves the gap conditions by increasing the energy of active sparks. Another effect is the
pressure differences in the discharge gap, primarily because of the presence of debris particles.
This facilitates relatively easy evacuation of the debris particles out of the gap [6]. Ultrasonic
vibrations of 40 kHz has been applied for drilling micro-holes of 40 µm, and the favorable effect
was found to be a lower tool wear ratio [7]. Recently, Che et al. [8]applied ultrasonic vibrations
to electrical discharge machining process and found that debris removal is equally effective for
the horizontal machine tool configuration. The external application of ultrasonic vibrations is
combined with abrasive jet machining [9], and with magnetic field [10]. In these new
investigations on hybrid techniques, an overall improvement in productivity and better surface
quality have been reported. In addition, attempts have been made to analyze the surface
morphology and characterize the mechanisms of machining.
There have only been a few attempts to characterize and analyze the effects of ultrasonic
vibrations on the main performance measures of micro-EDM. In one of such important
investigations [11], the best combination of parameters was identified by following the signal to
noise ratio approach based on Taguchi technique. Therefore, the objective of this paper is to
further analyze the effect of ultrasonic vibrations on the machining performance measures such as
tool electrode wear ratio, material removal rate and tool wear rate. This paper is divided into three
sections. In the first section, the tool wear ratio is calculated for different processing conditions
and its variation is estimated. The analysis of means method is used to analyze the MRR and
TWR data in the second section. In the third section, the results of regression analysis and the
developed regression equations are presented.
2. MATERIALS AND METHODS
The material A2 tool steel was used for the initial experimental investigation [11] based on which
this analysis is carried out. In the investigation, fine grinding was applied to finish the workpiece
surfaces. The chemical composition of AISI A2 tool steel is presented in Table 1.
Table 1. Chemical composition of A2 tool steel (%)
C Mn Cr Ni Mo V
1.00 1.00 5.0 0.3 1.0 0.15-0.50
3. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
3
The tool electrode of Ø200 µm was of material tungsten and was finished using wire electrical
discharge grinding. The ultrasonic vibration was provided to the workpiece using a piezoelectric
transducer of frequency 40 kHz and maximum amplitude of 10 µm in the vertical Z direction.
Fig. 1 shows the principle of vibration-assisted micro-EDM.
Fig. 1 A schematic of vibration-assisted micro-EDM (in the set-up: average frequency: 40 kHz, max.
amplitude: 10 µm)
Based on the experimental design using Taguchi L18 orthogonal array, actual experimentation
[11] and measurement of material removal from the workpiece and tool, the results of MRR and
TWR were obtained. The analysis using the data was done in three stages: i) analysis of tool
electrode wear ratio, ii) analysis of means of MRR and TWR, and iii) regression analysis.
Table 2 a-b shows the table for originating the graphs presented in Sections 3.2 and 3.3.
a. Input conditions
Capacitance (pF) 1000 ------ 3300
Percentage of peak power of vibration 0 30 60
Feedrate (µm/s) 1 3 5
b. Measurable process outputs
Trial # MRR (µm3
/min) TWR (µm3
/min) Tool wear ratio
1 500046 122460 0.244
2 414534 237070 0.572
3 427997 301440 0.704
4 1165085 248060 0.213
5 746397 422330 0.566
6 1362570 254340 0.186
7 905843 216660 0.239
8 1305570 406107 0.311
9 2057524 445880 0.217
10 855838 258527 0.302
11 1763868 364240 0.206
Electrod
Workpie
Dielectri
Micro-EDM process
4. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
4
Table 2 a-b The input conditions (a) and measurable process outputs (b) for analysis, the outputs presented
calculated based on [11] used for detailed analysis
3.RESULTS AND DISCUSSION
3.1 TOOL ELECTRODE WEAR RATIO
The calculated values of tool electrode wear ratio is presented in Fig. 2. The maximum tool wear
ratio for the investigation was 0.704 for the third trial,while the minimum was 0.128 for the
seventeenth trial. Hence, the extreme variation in the tool wear ratio for the investigation is found
to be 82%. The average value of tool wear ratio for the investigation is 0.308. The differences in
the magnitudes of tool electrode wear ratio indicates the variations in MRR and TWR, because of
the complexity of the physics of micro-EDM process. Therefore, a systematic analysis of means
is performed on the MRR and TWR data.
Fig. 2 The variation of tool electrode wear ratio in micro-EDM
3.2 ANALYSIS OF MEANS OF MRR
The main effects of the processing conditions on the MRR is evaluated in ultrasonic-vibration
assisted micro-EDM process. Fig. 3 a-d shows the AOM plots of MRR with capacitance (a),
percentage of peak power vibration (b), feed rate (c) and machining time (d). Though the effects
occur simultaneously during the spark machining, each effect is considered individually.
12 1345486 422330 0.314
13 975833 288880 0.296
14 1153642 320280 0.277
15 2444251 323420 0.132
16 928207 266900 0.287
17 1445989 185260 0.128
18 1222457 430180 0.352
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Toolwearratio
Trial numbers
5. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
5
a. b. c. d.
Fig. 3 a-d The AOM plots of MRR with the input factors
The capacitance (first factor) has only two levels in the L18 experimental design because its
variations are taken into account in the first column of the table [11]. As seen from Fig. 3-a, the
MRR decreases linearly with an increase in the capacitance. Normally, the discharge energy
varies linearly with the capacitance, and thus a linear increase in MRR is expected. However, in
some machining circumstances, when the feed rates are very small, most of the time is utilized
for movement of the tool electrode [12].
The AOM plot presented in Fig. 3-b shows that an increase in MRR is observed with an increase
in percentage of the power of ultrasonic vibrations. As the percentage of peak power of vibrations
increases from 0 to 30, the increase in MRR is seen to be 47%. The kinetic energy in the
ultrasonic vibrations helps reduce short-circuiting, reduce the number of inactive pulses and
removal of the debris particles from the discharge gap. However, with a further increase in peak
power, the rate of increase in MRR is decreased. This could be because of the heating effect at
higher levels of ultrasonic power, see Ref. [13].
The material removal rate increases linearly with an increase in the feed rate, see Fig. 3-c. The
MRR increases by 70% by the influence of federate. The feed rate causes an increase in the
action of flushing out the debris particles from the discharge gap, which has a positive effect on
the material removal [14]. The effect is further enhanced by the introduction of ultrasonic
vibrations. Considering the factor machining time, effect of its increase is to decrease the MRR,
see Fig. 3-d. With an increase in machining time, the depth of the cavity also increases. The
agglomeration of debris particles makes it very difficult to achieve stable sparking conditions.
The external application of ultrasonic vibrations are effective to some extent [15]. As can be seen
from Fig. 3-d, with an increase in machining time from 20 to 30 min, an increase in MRR by 7%
is achieved, which could be attributed to the effect of ultrasonic vibrations.
The interactions among the factors are considered for analysis and the interaction plots are
presented in Fig. 4. The total number of interactions are 6 and are: capacitance × percentage of
peak power of vibration, capacitance × federate, capacitance × machining time, percentage of
33001000
1600000
1500000
1400000
1300000
1200000
1100000
1000000
900000
800000
60300 531 302010
Capacitance (pF)
Mean
% of peak power vibration Feed rate (microm/sec) Machining time (min)
Main Effects Plot for MRR (micro-m3/min)
Data Means
6. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
6
peak power of vibration × federate, percentage of peak power of vibration × machining time and
federate × machining time. It is observed that when the factors interact, no specific favorable
effects are observed. In the interaction plot capacitance × federate, an overall increase in MRR is
observed. This could be attributed to the effect of ultrasonic vibrations to minimize arcing and
short-circuiting, effect of capacitance to concentrate higher discharge energy and the effect of
federate to increase the rate of machining. Fig. 5 a-d shows the three-dimensional scatter plots of
MRR with all the factors.
Fig. 4 Interaction plots for MRR
a.
b.
1000
2000
3
000060
0120000
000 01 08
10
0003
02
03
000 01 08
0000042
o-m3/min)rcim(RRM
gninicaM h )nim(emit
a )Fp(epaC citanc
1,0
5,2
,04
600000
0012000
08 00001
06
04
20
0
5,5
08 00001
0002400
MRR (micr i )nm/3m-o
vibrationrewopkaepfo%
eeeF d rat ( icrom/sec)m
7. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
7
c.
d.
Fig. 5 a-d The three-dimensional scatter plots for MRR with the controllable factors
3.3 ANALYSIS OF MEANS OF TWR
The effect of ultrasonic vibrations on the removal of material from the tool electrode is analyzed
using AOM plots for TWR. The results of analysis of means are presented in Fig. 6 a-d.
a. b. c. d.
Fig. 6 a-d The AOM plots of TWR with the input factors
The effect of capacitance on TWR is similar to that for MRR. A reduced transfer of discharge
energy to the tool electrode causes a decrease in the tool wear rate too (Fig. 6-a). The effect of
33001000
375000
350000
325000
300000
275000
250000
60300 531 302010
Capacitance (pF)
Mean
% of peak power vibration Feed rate (microm/sec) Machining time (min)
Data Means
0
20
40
600000
012000 0
08001 00
002 0
0001
60
03
002 0
000
08001 00
0042 000
MRR (micr m )ni/3m-o
citance (pF)apaC
wopof% kpea er vibration
10
02
6 00000
0000021
1 080000
2,5
,01
30
0,4
2,5
,55
1 080000
4002 000
ro-m3/min)cim(RRM
(eardeeF t )ces/morcim
a )nim(emichininM g t
8. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
8
ultrasonic vibration is to increase the tool wear rate. The effect is predominant at higher power of
peak vibration. This could be because of the effect of additional heating generated from the
vibrations (see Fig. 6-b). As the federate increases, the tool wear rate also increases significantly
(Fig. 6-c). This could be because of an increase in the frequency of interaction of the tool
electrode surface with the plasma channel. It can be observed from Fig. 6-d that an increase in
machining time from 20 to 30 min causes a decrease in the tool electrode wear. This effect could
be attributed to the effect of ultrasonic vibrations to flush out workpiece material without
consuming the tool electrode material. Fig. 7 shows the interaction plots for TWR. Three
dimensional scatter plots for TWR with all the controllable factors is presented in Fig. 8 a-d.
Fig. 7 Interaction plots for TWR
a. b.
c. d.
Fig. 8 a-d Three-dimensional scatter plots for TWR with the controllable factors
60300 531 302010
400000
300000
200000
400000
300000
200000
400000
300000
200000
Capacitance (pF)
% of peak power vibration
Feed rate (microm/sec)
Machining time (min)
1000
3300
(pF)
Capacitance
0
30
60
vibration
power
% of peak
1
3
5
(microm/sec)
Feed rate
0
20
40
100000
002 0 00
0300 00
0003
0020
0010
06
04 0000
TWR (m cri )nim/3m-o
apacitaC e )Fp(cn
noitarbivrewopo ka% epf
1,0
5,2
,4 0
000010
00002 0
0003 00
06
04
02
0
5,5
4 00000
icro-m3/min)m(RWT
opkaepfo% e noitarbivrw
e )ces/morcied rate (mF
10
20
000001
200 000
000003
2,5
1,0
03
0,4
2,5
,55
004 000
TWR (micr m )ni/3m-o
crom/sec)im(etardeeF
gachM inin ime (min)t
000100
000020
30 0000
0001
20 00
3
10
03 00
03
20
000 004
TWR (micr i )nm/3m-o
Machining )nim(emit
a )Fp(eticaC pa cn
9. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
9
3.4 REGRESSION ANALYSIS OF MRR AND TWR
Regression analysis method is used to determine the mathematical relationship between the
process outputs and the input factors. The regression equation for MRR is obtained as:
MRR = 1408227 – 157.0 × C + 7105 × P + 147060 × f – 27858 × Tm ……………………… (1),
where, C is the capacitance in pF, P is in percentage (%), f is the federate in µm/s and Tm is the
machining time in minutes.
S = 376455, R-sq = 62.73%
The residual plots for MRR are presented in Fig. 9.
Fig. 9 Residual plots for MRR
Regression analysis was performed on the TWR data, and the expression is:
TWR = 190580 – 9.9 × C + 680 × P + 32338 × f + 986 × Tm………..…………………….. (2)
S = 82453.7, R- sq = 39.91%
8000004000000-400000-800000
99
90
50
10
1
Residual
Percent
200000015000001000000500000
500000
250000
0
-250000
-500000
Fitted Value
Residual
6000004000002000000-200000-400000-600000
4,8
3,6
2,4
1,2
0,0
Residual
Frequency
18161412108642
500000
250000
0
-250000
-500000
Observation Order
Residual
Normal Probability Plot Versus Fits
Histogram Versus Order
Residual Plots for MRR (micro-m3/min)
10. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
10
Fig. 10 shows the residual plots for TWR.
4. CONCLUSIONS
The effect of ultrasonic vibrations on the performance of micro-EDM in machining A2 tool steel
is systematically analyzed and presented in this paper. The main favorable effect of ultrasonic
vibrations is to effectively evacuate debris from the discharge gap even at higher machining
depths. As a result, an increase in MRR and, at the same time, a decrease in TWR could be
observed at higher machining depths. The effects of capacitance, percentage of peak ultrasonic
vibrations, federate and machining time on MRR and TWR have been analyzed. Based on this
work, the following conclusions can be derived:
• The tool wear ratio for the process was calculated at various processing conditions. A
maximum variation in the tool wear ratio of 82% was observed in the process for the
selected processing conditions. This could be because of the larger range of parameters
chosen for the investigation.
• An increase in MRR is observed with an increase in percentage of the power of ultrasonic
vibrations. As the percentage of peak power of vibrations increases from 0 to 30%, the
increase in MRR is seen to be 47%. The kinetic energy in the ultrasonic vibrations helps
reduce short-circuiting, reduce the number of inactive pulses and removal of the debris
particles from the discharge gap.
• The effect of ultrasonic vibration is to increase the tool wear rate. As the percentage of
peak power of vibrations increases from 0 to 60%, an increase in TWR is observed to be
18%. The effect is predominant at higher power of peak vibration. This could be because
of the effect of additional heating generated from the vibrations
• With an increase in machining time from 20 to 30 min, an increase in MRR by 7% is
achieved, which could be attributed to the effect of ultrasonic vibrations. At lower depths
of machining, the mechanism of flushing out the eroded particles with the jet of liquid
2000001000000-100000-200000
99
90
50
10
1
Residual
Percent
400000350000300000250000200000
100000
0
-100000
Fitted Value
Residual
150
000
100
000
50
0000
-50
000
-100
000
-150
000
4
3
2
1
0
Frequency
18161412108642
100000
0
-100000
Observation Order
Residual
Normal Probability Plot Versus Fits
Histogram Versus Order
11. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.5, No.3, August 2016
11
dielectric is not effective. The ultrasonic vibrations transfers the kinetic energy to the
debris particles and helps flush the particles out.
• An increase in machining time from 20 to 30 min causes a decrease in the tool electrode
wear. This effect could be attributed to the effect of ultrasonic vibrations to flush out
workpiece material without consuming the tool electrode material.
• Regression equations were developed for MRR and TWR, by considering the effect of all
the input factors.
ACKNOWLEDGEMENTS
The author would like to acknowledge the support from H.C. Ørsted COFUND postdoc
fellowship.
REFERENCES
[1] Kunieda, M., Lauwers, B., Rajurkar, K. P. and Schumaker, B. M. (2005), Advancing EDM through
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