IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using different electrode materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Experimental Study with Rotating Tool Electrode of EDM for NiAlloyIJMER
Conventional machining process has the limitation when desired surface finish and
dimensional accuracy in geometry is required in difficult to machine aerospace materials especially for
the cases of drilling holes. Non conventional advance machining processes (AMPs) are extensively used
in the industry to machine for the complex geometrical dimension along with desired surface finish in
hard materials. Electrical Discharge machining with modification for holding and rotating the
electrode has been used in the present experiment for making holes in the Nimonic alloy. This paper
investigate the influence of gap current, pulse on time, duty factor, tool electrode rpm and especially the
polarity of the machine on Material Removal Rate (MRR) and surface roughness (Ra) for machining of
Nimonic alloy. It is observed that with suitable control of input parameters of Electrical Discharge
drilling (EDD), MRR and Ra both found to be improving together from 60 to 90 mg and 4.8 to 2.9 µm
respectively which confirm the viability of using tool electrode rotation in EDM machining.
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.
This document reviews various welding techniques. It begins by introducing welding as a process for joining materials like metals through melting and discusses some common welding techniques like shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, and flux-cored arc welding. The document then reviews literature on optimizing welding parameters and their effects on weld properties. Specifically, it looks at research optimizing parameters for gas metal arc welding, gas tungsten arc welding and submerged arc welding. The document describes the methodology for conducting experiments on gas metal arc welding and gas tungsten arc welding of austenitic stainless steel to analyze properties like hardness, strength and corrosion resistance under varied welding conditions.
Analysis of Machining Characteristics of Cryogenically Treated Die Steels Usi...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.
This document describes a study that used Response Surface Methodology (RSM) to optimize the Wire Electric Discharge Machining (WEDM) process for D-2 tool steel. RSM and a central composite design were used to develop models for how the material removal rate (MRR) responds to four machining parameters: pulse on time, pulse off time, peak current, and servo voltage. 30 experiments were conducted according to the design. The results showed that MRR increases with pulse on time and peak current, but decreases with pulse off time and servo voltage.
This document summarizes research on laser beam machining (LBM), which uses a focused laser beam to vaporize material. It discusses LBM principles, modeling and simulation methods, applications for micromachining, effects of process parameters on cut quality, and optimization of parameters. Key findings include that laser power, cutting speed, and assist gas pressure are most important parameters affecting surface roughness and kerf width. LBM allows high-precision cutting of almost any material but optimization of parameters is needed to minimize defects and improve cut quality. Research aims to better understand LBM through modeling and relate process parameters to quality metrics to optimize the process.
Material Removal Rate, Tool Wear Rate and Surface Roughness Analysis of EDM P...ijsrd.com
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using different electrode materials has been carried out. The Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) is measured and recorded for detailed analysis. Different electrode
Research paper published ijsrms_process optimization using doe_edm_javed muja...vishwajeet potdar
This document summarizes research on optimizing surface roughness in electric discharge machining (EDM) using design of experiments (DOE). It first provides background on EDM and discusses how surface roughness influences part life in die-mold applications. The document then reviews previous research optimizing EDM performance measures like material removal rate, tool wear rate, and surface roughness using Taguchi methods and analyzing the effects of parameters like discharge current and pulse duration. The goal of the current research is to use DOE to determine suitable levels for significant EDM input parameters to optimize the process for achieving a desired surface roughness value under given operating conditions.
Experimental Study with Rotating Tool Electrode of EDM for NiAlloyIJMER
Conventional machining process has the limitation when desired surface finish and
dimensional accuracy in geometry is required in difficult to machine aerospace materials especially for
the cases of drilling holes. Non conventional advance machining processes (AMPs) are extensively used
in the industry to machine for the complex geometrical dimension along with desired surface finish in
hard materials. Electrical Discharge machining with modification for holding and rotating the
electrode has been used in the present experiment for making holes in the Nimonic alloy. This paper
investigate the influence of gap current, pulse on time, duty factor, tool electrode rpm and especially the
polarity of the machine on Material Removal Rate (MRR) and surface roughness (Ra) for machining of
Nimonic alloy. It is observed that with suitable control of input parameters of Electrical Discharge
drilling (EDD), MRR and Ra both found to be improving together from 60 to 90 mg and 4.8 to 2.9 µm
respectively which confirm the viability of using tool electrode rotation in EDM machining.
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.
This document reviews various welding techniques. It begins by introducing welding as a process for joining materials like metals through melting and discusses some common welding techniques like shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, and flux-cored arc welding. The document then reviews literature on optimizing welding parameters and their effects on weld properties. Specifically, it looks at research optimizing parameters for gas metal arc welding, gas tungsten arc welding and submerged arc welding. The document describes the methodology for conducting experiments on gas metal arc welding and gas tungsten arc welding of austenitic stainless steel to analyze properties like hardness, strength and corrosion resistance under varied welding conditions.
Analysis of Machining Characteristics of Cryogenically Treated Die Steels Usi...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.
This document describes a study that used Response Surface Methodology (RSM) to optimize the Wire Electric Discharge Machining (WEDM) process for D-2 tool steel. RSM and a central composite design were used to develop models for how the material removal rate (MRR) responds to four machining parameters: pulse on time, pulse off time, peak current, and servo voltage. 30 experiments were conducted according to the design. The results showed that MRR increases with pulse on time and peak current, but decreases with pulse off time and servo voltage.
This document summarizes research on laser beam machining (LBM), which uses a focused laser beam to vaporize material. It discusses LBM principles, modeling and simulation methods, applications for micromachining, effects of process parameters on cut quality, and optimization of parameters. Key findings include that laser power, cutting speed, and assist gas pressure are most important parameters affecting surface roughness and kerf width. LBM allows high-precision cutting of almost any material but optimization of parameters is needed to minimize defects and improve cut quality. Research aims to better understand LBM through modeling and relate process parameters to quality metrics to optimize the process.
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
IRJET- Influence of Process Parameters on Welded Joint by Laser Beam WeldingIRJET Journal
The document discusses optimizing process parameters for laser beam welding. It examines how laser power, welding speed, and diameter of the laser beam influence tensile strength, weld hardness, and percentage elongation in welded joints. Experiments were conducted using stainless steel plates welded with varying levels of the three parameters. Tensile strength, hardness, and elongation results were highest when using a laser power of 350W, welding speed of 0.5mm/sec, and diameter of 0.40mm. The proposed Taguchi method and gray relational analysis provide an effective way to optimize welding quality without extensive experimentation.
PARAMETRIC OPTIMIZATION OF ELECTROCHEMICAL MACHININGAnmol Mangat
1. The document discusses parametric optimization of electrochemical machining (ECM). ECM is a non-traditional machining process that removes metal through reverse electroplating. It can machine hard metals and complex geometries.
2. The author designs and fabricates an ECM machine to surface finish cylindrical workpieces. Experiments are conducted to analyze the effect of voltage, time, and revolutions per minute on surface finish improvement percentage.
3. A relationship between process parameters and output characteristics is developed using a design of experiment approach to optimize the ECM process for improving surface finish.
Optimization of Laser Welding Parameters: A ReviewIRJET Journal
This document reviews research on optimizing laser welding parameters. It summarizes 10 studies that investigated how varying parameters like laser power, welding speed, focal length, and shielding gas affected weld characteristics for different materials. Most found laser power and welding speed were most significant and that their combination mainly determines weld quality. Optimal parameters depended on the material and goals for responses like weld width, penetration, and strength. The studies used techniques like factorial design of experiments, response surface methodology, and Taguchi methods to optimize parameters and reduce defects for applications like welding steel, titanium alloys, and dissimilar metals.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
Study on Influence of heat treatment on Tribological properties of mild steeldbpublications
A study was made on the effect of heat treatment upon the mild steel. Total six samples were prepared for each test (hardness test, tensile test, microstructure test and wear test) from those two was tested as received and rest four were subjected to different heat treatment that are annealing and normalizing (heated on a temperature of 850 degree Celsius). The hardness of all sample was measured by Rockwell hardness testing machine. Wear measurement was done on pin-on disc wear machine. Tensometer was used to find out the ultimate stress and strain of the sample. The result of tensile test showed that the strength is decreased by heat treating and the surface hardness is also decreased by heat treatment. Microstructure of the mild steel specimens shows the grain boundary of the particles and the content of % of carbon present. It justifies the experimental results of tensile test and hardness test. Surface Hardness is the measure of resistance that any material applies. As the specimen gets soft on treating the hardness also gets decreased. Tensile strength of any specimen is specified as how much stress the material can withstand before breaking. As the metal gets soft after heat treatment the load required for breaking goes on decreasing. Wear test is carried out to see the variation in wear measurement and coefficient of friction as the mesh size of paper are varied. More soft the surface of material is more wear is seen and vice-versa.
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.
IRJET- A Review on Parametric Optimization of Aluminium Alloy 5754 For MI...IRJET Journal
This document reviews research on optimizing parameters for metal inert gas (MIG) welding of aluminum alloy 5754. MIG welding parameters like current, voltage, welding speed, wire feed rate, and gas flow rate influence properties of the weld like strength, geometry, and microstructure. Previous studies optimized these parameters using Taguchi methods to obtain the best combination for quality. One study found that increasing voltage and gas flow rate while decreasing current improved weld strength. High-speed imaging was also used to show that continuous and pulsed ultrasonic-assisted MIG welding reduce necking and increase penetration compared to conventional MIG. Overall, the document discusses how optimization of MIG parameters can improve weld quality for aluminum alloy 5754
Gray Relational Basedanalysis of Tool SteelIRJET Journal
This document presents research on optimizing the electro discharge machining (EDM) process for tool steel using Taguchi methods and grey relational analysis. The researchers conducted experiments with tool steel as the workpiece material and copper as the electrode. Response variables included material removal rate (MRR) and surface roughness (Ra). Taguchi methods were used to design the experiments and orthogonal arrays. Grey relational analysis was then used to analyze the multiple responses and determine the optimal process parameters. The analysis involved normalizing the experimental data, calculating grey relational coefficients and grades, and analyzing the results using ANOVA to select parameters that maximize MRR and minimize Ra.
Prediction of Weld Quality of A Tungsten Inertr Gas Welded Mild Steel Pipe Jo...IJERA Editor
The weld quality of tungsten inert gas (TIG) welded joint has been investigated to identify the most economical weld parameters that will bring about optimum properties. Response surface methodology has been used in the optimization of the tungsten inert gas weld of mild steel pipes. Response surface methodology, based on the central composite face centered design was generated for the purpose of optimization of the weld quality.All the process parameters have desirability of 1. Tensile strength response for this solution have a desirability of 0.910595 and the yield strength of 0.59. Result showed that minimizing current and voltage an average tensile strength of 535.452MPa and yield strength of up to 408.74MPa can be achieved, while keeping gas flow rate and electrode diameter within the range of test. It was also deduced that tensile elongation of the TIG weld is not influenced by the process parameters selected for the purpose of this study.
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
FEM Analysis of Stress Predication of Aluminum Wire Rod in Drawing OperationIRJET Journal
This document analyzes aluminum wire drawing operations to understand causes of wire breakage. Finite element analysis is conducted using ANSYS to simulate wire stresses, strains, die stresses, and temperatures at critical drawing stages. The analysis considers different friction conditions to find optimal parameters that minimize defects and breakage. Material properties of the aluminum alloy wire and polycrystalline dies are defined. Simulation results reveal plastic deformation patterns and maximum stresses under various lubrication conditions to suggest preventative measures and reduce breakage during drawing.
IRJET- Analysis of Process Parameters of Plasma ARC Cutting using Design of E...IRJET Journal
This document discusses the analysis of process parameters for plasma arc cutting using design of experiments. The study aims to determine the optimum parameter settings to achieve maximum material removal rate (MRR) and minimum surface roughness (Ra). Sixteen experiments were conducted using a Taguchi orthogonal array with four parameters (gas pressure, current, cutting speed, arc gap) each at two levels. Stainless steel samples were cut and the MRR and Ra values measured. ANOVA and other analyses were used to evaluate the effect of each parameter and identify the optimal settings for MRR and Ra.
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.
This document discusses research on using extrusion honing (EH) to improve the surface finish of Inconel 625 fabricated by electric discharge machining (EDM). EH involves flowing an abrasive-laden polymer media over a material's surface to deburr, polish, and remove defects. The study investigated the effect of EH process parameters on the surface roughness of square Inconel 625 samples. Results showed that EH significantly improved surface finish by removing microcracks and recast layers from EDM. Surface roughness decreased dramatically in the first few EH passes then continued to gradually improve up to the 11th pass. Scanning electron microscope images confirmed that EH successfully removed defects from EDM.
Experimental evaluation of performance of electrical discharge machining of d...eSAT Journals
Abstract Electrical discharge machining is the most widely used machining process in industries. Its use is particularly intense when very complex shapes on hard materials with a high dimensional accuracy are required. However the technological capability of the process has limited application when there is a requirement of high surface quality and mirror like characteristics. Its operation is characterized by long machining time, high tool wear and uncertainty in the final finish of the surface. However for finish surface, materials are subjected to mechanical polishing after EDM, which is wastage of time and energy. To improve the efficiency and surface finish of the work piece, the abrasive particles of Aluminum oxide (Al2O3 ) are mixed into the dielectric fluid at tool-work interface. In this Abrasive mixed EDM, the Abrasive mixed dielectric fluid facilitate the bridging effect and minimize the insulating strength of the dielectric fluid. As a result it improves the material removal rate and surface roughness. This paper presents the effect of abrasive on the performance of the EDM process. The results of both the processes have been analyzed using Design of experiments to find the significant parameters and to obtain the optimum parameters required for machining. Analyzed results indicate that abrasive particle size and abrasive concentration and pulse current are the most significant parameters that improve the material removal rate in comparison with traditional EDM. A new experimental setup is developed for experimentation. The result shows that the MRR increases with the abrasive mixed EDM. Keywords: Material removal rate, Abrasive mixed EDM, Dielectric fluid, Design of experiment, Abrasive particle size.
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
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document discusses collision avoidance mechanisms in wireless ad hoc networks using distributed medium access control (MAC) protocols. It analyzes two main approaches for collision avoidance - out-of-band signaling using a busy tone, and an in-band handshaking approach using request-to-send and clear-to-send messages. The hidden node problem is a major cause of collisions at intermediate nodes in ad hoc networks, so the goal is to reduce collisions and improve transmission reliability. Algorithms for collision avoidance at intermediate nodes are presented for both the out-of-band and in-band approaches.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
The document summarizes research on controlling tool wear during electrical discharge machining (EDM). It discusses how tool wear reduces accuracy by diminishing feature sharpness and increases costs. The research aims to identify factors influencing the rate of tool wear and optimize parameters like current and pulse time to minimize wear of copper electrodes. It reviews past studies on improving material removal rate and reducing tool wear rate through techniques like using powder metallurgy to create copper-tungsten electrodes and implementing Taguchi methods for optimization. The presented research will experimentally validate solutions for controlling tool wear during EDM of copper electrodes.
IRJET- Influence of Process Parameters on Welded Joint by Laser Beam WeldingIRJET Journal
The document discusses optimizing process parameters for laser beam welding. It examines how laser power, welding speed, and diameter of the laser beam influence tensile strength, weld hardness, and percentage elongation in welded joints. Experiments were conducted using stainless steel plates welded with varying levels of the three parameters. Tensile strength, hardness, and elongation results were highest when using a laser power of 350W, welding speed of 0.5mm/sec, and diameter of 0.40mm. The proposed Taguchi method and gray relational analysis provide an effective way to optimize welding quality without extensive experimentation.
PARAMETRIC OPTIMIZATION OF ELECTROCHEMICAL MACHININGAnmol Mangat
1. The document discusses parametric optimization of electrochemical machining (ECM). ECM is a non-traditional machining process that removes metal through reverse electroplating. It can machine hard metals and complex geometries.
2. The author designs and fabricates an ECM machine to surface finish cylindrical workpieces. Experiments are conducted to analyze the effect of voltage, time, and revolutions per minute on surface finish improvement percentage.
3. A relationship between process parameters and output characteristics is developed using a design of experiment approach to optimize the ECM process for improving surface finish.
Optimization of Laser Welding Parameters: A ReviewIRJET Journal
This document reviews research on optimizing laser welding parameters. It summarizes 10 studies that investigated how varying parameters like laser power, welding speed, focal length, and shielding gas affected weld characteristics for different materials. Most found laser power and welding speed were most significant and that their combination mainly determines weld quality. Optimal parameters depended on the material and goals for responses like weld width, penetration, and strength. The studies used techniques like factorial design of experiments, response surface methodology, and Taguchi methods to optimize parameters and reduce defects for applications like welding steel, titanium alloys, and dissimilar metals.
Experimental Investigation of Process Parameters on Inconel 925 for EDM Proce...Vishal Kumar Jaiswal
Experimental Investigation of Process Parameters on Inconel 925 for EDM Process by using Taguchi Method
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://www.ijsrd.com/articles/IJSRDV6I50198.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50198
Study on Influence of heat treatment on Tribological properties of mild steeldbpublications
A study was made on the effect of heat treatment upon the mild steel. Total six samples were prepared for each test (hardness test, tensile test, microstructure test and wear test) from those two was tested as received and rest four were subjected to different heat treatment that are annealing and normalizing (heated on a temperature of 850 degree Celsius). The hardness of all sample was measured by Rockwell hardness testing machine. Wear measurement was done on pin-on disc wear machine. Tensometer was used to find out the ultimate stress and strain of the sample. The result of tensile test showed that the strength is decreased by heat treating and the surface hardness is also decreased by heat treatment. Microstructure of the mild steel specimens shows the grain boundary of the particles and the content of % of carbon present. It justifies the experimental results of tensile test and hardness test. Surface Hardness is the measure of resistance that any material applies. As the specimen gets soft on treating the hardness also gets decreased. Tensile strength of any specimen is specified as how much stress the material can withstand before breaking. As the metal gets soft after heat treatment the load required for breaking goes on decreasing. Wear test is carried out to see the variation in wear measurement and coefficient of friction as the mesh size of paper are varied. More soft the surface of material is more wear is seen and vice-versa.
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.
IRJET- A Review on Parametric Optimization of Aluminium Alloy 5754 For MI...IRJET Journal
This document reviews research on optimizing parameters for metal inert gas (MIG) welding of aluminum alloy 5754. MIG welding parameters like current, voltage, welding speed, wire feed rate, and gas flow rate influence properties of the weld like strength, geometry, and microstructure. Previous studies optimized these parameters using Taguchi methods to obtain the best combination for quality. One study found that increasing voltage and gas flow rate while decreasing current improved weld strength. High-speed imaging was also used to show that continuous and pulsed ultrasonic-assisted MIG welding reduce necking and increase penetration compared to conventional MIG. Overall, the document discusses how optimization of MIG parameters can improve weld quality for aluminum alloy 5754
Gray Relational Basedanalysis of Tool SteelIRJET Journal
This document presents research on optimizing the electro discharge machining (EDM) process for tool steel using Taguchi methods and grey relational analysis. The researchers conducted experiments with tool steel as the workpiece material and copper as the electrode. Response variables included material removal rate (MRR) and surface roughness (Ra). Taguchi methods were used to design the experiments and orthogonal arrays. Grey relational analysis was then used to analyze the multiple responses and determine the optimal process parameters. The analysis involved normalizing the experimental data, calculating grey relational coefficients and grades, and analyzing the results using ANOVA to select parameters that maximize MRR and minimize Ra.
Prediction of Weld Quality of A Tungsten Inertr Gas Welded Mild Steel Pipe Jo...IJERA Editor
The weld quality of tungsten inert gas (TIG) welded joint has been investigated to identify the most economical weld parameters that will bring about optimum properties. Response surface methodology has been used in the optimization of the tungsten inert gas weld of mild steel pipes. Response surface methodology, based on the central composite face centered design was generated for the purpose of optimization of the weld quality.All the process parameters have desirability of 1. Tensile strength response for this solution have a desirability of 0.910595 and the yield strength of 0.59. Result showed that minimizing current and voltage an average tensile strength of 535.452MPa and yield strength of up to 408.74MPa can be achieved, while keeping gas flow rate and electrode diameter within the range of test. It was also deduced that tensile elongation of the TIG weld is not influenced by the process parameters selected for the purpose of this study.
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
FEM Analysis of Stress Predication of Aluminum Wire Rod in Drawing OperationIRJET Journal
This document analyzes aluminum wire drawing operations to understand causes of wire breakage. Finite element analysis is conducted using ANSYS to simulate wire stresses, strains, die stresses, and temperatures at critical drawing stages. The analysis considers different friction conditions to find optimal parameters that minimize defects and breakage. Material properties of the aluminum alloy wire and polycrystalline dies are defined. Simulation results reveal plastic deformation patterns and maximum stresses under various lubrication conditions to suggest preventative measures and reduce breakage during drawing.
IRJET- Analysis of Process Parameters of Plasma ARC Cutting using Design of E...IRJET Journal
This document discusses the analysis of process parameters for plasma arc cutting using design of experiments. The study aims to determine the optimum parameter settings to achieve maximum material removal rate (MRR) and minimum surface roughness (Ra). Sixteen experiments were conducted using a Taguchi orthogonal array with four parameters (gas pressure, current, cutting speed, arc gap) each at two levels. Stainless steel samples were cut and the MRR and Ra values measured. ANOVA and other analyses were used to evaluate the effect of each parameter and identify the optimal settings for MRR and Ra.
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.
This document discusses research on using extrusion honing (EH) to improve the surface finish of Inconel 625 fabricated by electric discharge machining (EDM). EH involves flowing an abrasive-laden polymer media over a material's surface to deburr, polish, and remove defects. The study investigated the effect of EH process parameters on the surface roughness of square Inconel 625 samples. Results showed that EH significantly improved surface finish by removing microcracks and recast layers from EDM. Surface roughness decreased dramatically in the first few EH passes then continued to gradually improve up to the 11th pass. Scanning electron microscope images confirmed that EH successfully removed defects from EDM.
Experimental evaluation of performance of electrical discharge machining of d...eSAT Journals
Abstract Electrical discharge machining is the most widely used machining process in industries. Its use is particularly intense when very complex shapes on hard materials with a high dimensional accuracy are required. However the technological capability of the process has limited application when there is a requirement of high surface quality and mirror like characteristics. Its operation is characterized by long machining time, high tool wear and uncertainty in the final finish of the surface. However for finish surface, materials are subjected to mechanical polishing after EDM, which is wastage of time and energy. To improve the efficiency and surface finish of the work piece, the abrasive particles of Aluminum oxide (Al2O3 ) are mixed into the dielectric fluid at tool-work interface. In this Abrasive mixed EDM, the Abrasive mixed dielectric fluid facilitate the bridging effect and minimize the insulating strength of the dielectric fluid. As a result it improves the material removal rate and surface roughness. This paper presents the effect of abrasive on the performance of the EDM process. The results of both the processes have been analyzed using Design of experiments to find the significant parameters and to obtain the optimum parameters required for machining. Analyzed results indicate that abrasive particle size and abrasive concentration and pulse current are the most significant parameters that improve the material removal rate in comparison with traditional EDM. A new experimental setup is developed for experimentation. The result shows that the MRR increases with the abrasive mixed EDM. Keywords: Material removal rate, Abrasive mixed EDM, Dielectric fluid, Design of experiment, Abrasive particle size.
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
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document discusses collision avoidance mechanisms in wireless ad hoc networks using distributed medium access control (MAC) protocols. It analyzes two main approaches for collision avoidance - out-of-band signaling using a busy tone, and an in-band handshaking approach using request-to-send and clear-to-send messages. The hidden node problem is a major cause of collisions at intermediate nodes in ad hoc networks, so the goal is to reduce collisions and improve transmission reliability. Algorithms for collision avoidance at intermediate nodes are presented for both the out-of-band and in-band approaches.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
This document presents a proposed method for efficient image compression using integer wavelet transform (IWT) employing the lifting scheme (LS). The lifting scheme allows for faster computation compared to conventional discrete wavelet transform by exploiting both high-pass and low-pass filter values. Simulation results using MATLAB show the proposed method achieves superior compression performance in terms of encoding time, decoding time, peak signal-to-noise ratio, and compression ratio for various test images. The integer wavelet transform with lifting scheme provides a robust algorithm for truly lossless image compression by decomposing both approximation and detailed image contents.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document describes Wise Store, a new model for organizing file metadata in large-scale distributed storage systems. Wise Store uses semantic grouping to organize metadata in a decentralized manner, constructing a semantic R-tree across storage units. This improves scalability and supports efficient composite queries like range, top-k, and search queries. Wise Store reduces query latency for these advanced metadata queries in systems with billions of files and exabytes of storage. It also enhances security using RSA encryption of metadata.
The document investigates the effect of classroom amplification on students' listening behavior in Akwa Ibom State, Nigeria. It found a high correlation (0.87) between teachers' ratings of listening behavior in amplified classrooms and the signal-to-noise ratio of amplified teacher speeches. Teachers rated listening behavior as excellent for 14.5% of students, very high for 53%, and good for 22.3%. This shows that classroom amplification improves the SNR and positively influences student listening. It is recommended that students be taught in amplified classrooms to enhance listening, attention, and academic performance.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document discusses a proposed method for color image authentication using digital image watermarking and histograms. It begins with an abstract describing the goal of robust digital color image watermarking for authentication while minimizing embedding distortion. It then provides background on digital watermarking techniques and reviews some previous related works. The proposed method embeds a watermark into the least significant bit of each color plane (red, green, blue) of the cover image. It describes the insertion and extraction algorithms in detail. Experimental results on test images are provided, analyzing the peak signal-to-noise ratio for each color plane between the original and watermarked images. The method is concluded to enhance visibility and robustness of the watermark for image authentication.
This document summarizes a research paper that proposes using a genetic algorithm to optimize test time and test access mechanism (TAM) length for three-dimensional system-on-chip (3D SoC). It describes challenges in testing 3D SoCs, such as pre-bond and post-bond testing. It presents a genetic algorithm that represents solutions as chromosomes encoding TAM partitioning, width distribution, and core/layer assignments. The algorithm aims to minimize total test time and TAM length by evolving populations of solutions until an optimal one is found. Experimental results on benchmark circuits showed improved test times over previous methods.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Las mujeres celtas gozaban de gran libertad y autonomía. Eran libres de elegir a sus parejas y nunca podían ser forzadas a una relación no deseada. Se les enseñaba a valerse por sí mismas y a ser buenas amantes, amas de casa y madres. La principal enseñanza era amar y seguir a su pareja si esta representaba los valores de amor, compañerismo y amistad enseñados por la Diosa Madre.
El documento describe las características principales de la Web 2.0 y sus implicaciones educativas. Permite buscar, crear y compartir contenido de forma colaborativa e interactiva, proporcionando espacios en línea para almacenar y difundir información de varios formatos. Esto facilita nuevas actividades de aprendizaje y la creación de redes entre estudiantes, con un rol más autónomo y crítico para profesores y alumnos.
El documento describe varios proyectos relacionados con la potabilización de agua, depuración de aguas residuales, reutilización de aguas tratadas, sellado de vertederos y cogeneración de biogás en los que ha participado. Los proyectos incluyen plantas potabilizadoras, desnitrificadoras, depuradoras de aguas residuales urbanas e industriales, y sistemas de tratamiento terciario y reutilización en varias localidades de España y Brasil.
Las tecnologías de la información (TI) son fundamentales para todas las áreas y procesos de una empresa. Permiten mejorar la comunicación con clientes, proveedores y empleados, así como aumentar la productividad y la ventaja competitiva. La implementación de sistemas de TI requiere de una buena planificación y formación para integrarlos correctamente y obtener los mayores beneficios.
A Literature Review on Fiber Laser Cutting on Stainless Steel-304ijsrd.com
the recent up gradation of newer and high strength materials have made the machining task in fiber laser cutting is quite challenging. Thus for the optimum use of all the resources it is essential to make the required mechanical properties, accuracy and quality. This paper reviews the various notable works in field of Fiber Laser Cutting and magnifies on effect of machining parameters on strength, kerf width and surface roughness.
At present scenario, INCONEL alloy 625 becomes widely used material in aero industry due to its High
tensile, creep, and rupture strength, outstanding fatigue and thermal-fatigue strength, oxidation resistance, and
excellent weld ability properties. In present work, the plates of 50mm×50mm×3mm are modelled and assembled
for v-butt joint using solid works. This model is imported in the FEA software (ANSYS) to carry out the transient
thermal analysis. The analysis is carried out with different combinations of welding parameters such as voltage,
current, velocity, speed and melting efficiency. From the analysis result, the temperature distribution at various
locations around the weld bead is evaluated. From structural analysis result, the distortion of work piece due to the
thermal effect is analysed.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
This document discusses the industrial applications of carbon dioxide lasers for cutting and drilling. CO2 lasers are commonly used due to their high output power and ability to operate continuously for long periods of time. Some key applications discussed are laser cutting of metals and non-metals, which works by producing a series of overlapping holes along the cut line. Laser drilling is also discussed as a growing application, allowing for precision drilling of hard and soft materials without tool wear. Overall, CO2 laser machining plays an important role in manufacturing due to its precision, accuracy and ability to process a variety of materials with minimal heat effects.
Optimizing Process Parameters on SR and MRR of Steel by EDMIRJET Journal
This document summarizes an experiment that optimized process parameters for electric discharge machining (EDM) of steel to improve material removal rate (MRR) and surface roughness (SR). Stainless steel 316 samples were machined using a copper electrode. A pilot study tested different levels of discharge current, pulse on-time, pulse off-time, and dielectric pressure. Graphs showed that MRR increased with higher current due to increased spark intensity and melting/vaporization, while SR also increased with higher current. MRR decreased with longer pulse on-time due to a wider plasma channel. Based on the pilot study, a Taguchi L18 design of experiments was used to further test current, pulse on-time,
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
A Review Study of Investigation on Titanium Alloy Coatings for Wear Resistanc...IRJET Journal
This document summarizes a review study investigating titanium alloy coatings deposited via physical vapor deposition (PVD) for improved wear resistance. PVD was identified as a cost-effective coating method that provides benefits like superior wear and corrosion resistance as well as low friction. The coatings were deposited on mild steel substrates for pump shaft applications. Characterization techniques like X-ray diffraction and ball-on-disc testing were used to analyze the coatings. The literature review discussed various coating materials, deposition methods, and experimental factors related to evaluating PVD coatings for wear resistance.
Investigation on process response and parameters in wire electrical discharge...IAEME Publication
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
Investigation on process response and parameters in wire electricalIAEME Publication
This document summarizes a study that investigated the effects of process parameters on wire electrical discharge machining (WEDM) of Inconel 625. The study used Taguchi's design of experiments methodology to determine the optimal levels of six machining parameters (pulse-on time, pulse-off time, wire feed, upper flush, lower flush, wire tension) for minimizing kerf width, electrode wire wear, and maximizing surface hardness. Twenty-five experiments were conducted according to an L25 orthogonal array. Regression analysis was used to establish relationships between the process parameters and responses. The results showed good agreement between experimental and predicted values, demonstrating the methodology can determine optimal machining conditions for WEDM of Inconel
Investigation on process response and parameters in wire electricaliaemedu
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
Study on laser hardening parameters of ASTM Grade 3 pure titanium on an angle...Premier Publishers
This research paper includes the laser transformation hardening of commercially pure titanium sheet of 1.6mm thickness is investigated using CW Nd:YAG laser. Commercially pure titanium has prevalent application in various fields of industries including the medical, nuclear, thermal, marine, defense, automobile aerospace and pharmaceutical industries. A FFD with RSM is employed to establish, optimize and to investigate the relationships of three laser transformation hardening process parameters: laser power, scanning speed, and focused position on laser hardened bead profile parameters such as angle of entry of hardened bead profile and power density. RSM is used to develop pseudo-closed-form models from the computational parametric studies. Adequacies of developed models were analyzed by ANOVA. Effects of laser process parameters on an angle of entry of hardened bead profile and power density were also carried out using RSM. The laser power and scanning speed consecutively have a positive and significant effect on angle of entry of hardened bead profile and power density respectively as compared to the focal point position among all laser hardening process parameters. The optimum laser hardening conditions are identified sequentially to minimize an angle of entry of hardened profile, power density. The validation results demonstrate that the developed models are accurate with low percentages of error.
This document summarizes a numerical simulation of laser beam micro machining of 304 stainless steel. A finite element analysis was conducted using ABAQUS software to analyze the temperature distributions and determine the kerf width and depth. Both continuous wave and pulsed laser beams were modeled, including variations of laser power and cutting speed. Temperature dependent material properties were considered. The results found that increasing laser power increases the maximum temperature, and finer meshing improves accuracy but increases simulation time. The analysis aims to understand temperature distributions during laser machining of stainless steel.
SIMULATION OF DEEP DRAWING DIE FOR OPTIMIZED DIE RADIUS USING FEM TECHNIQUEIjripublishers Ijri
Deep drawing process is one of the most used Metal Forming Process within the industrial field. Different analytical,
numerical, empirical and experimental methods have been developed in order to analyze it. This work reports on the
initial stages of finite element analysis (FEA) of a Deep drawing process.
Research Inventy : International Journal of Engineering and Scienceinventy
esearch Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
REVIEW ON EFFECT OF HEAT INPUT ON TENSILE STRENGTH OF BUTT WELD JOINT USING M...ijiert bestjournal
This document summarizes a research paper that investigated the effect of heat input on the tensile strength of butt weld joints using MIG welding. The researchers found that increasing heat input affected the microstructure of the base metal and heat affected zone. Tensile strength decreased with higher heat input. Microhardness was observed to increase in the weld pool but decrease in the heat affected zone with greater heat input. Optical microscopy showed smaller dendrite sizes and spacing at low heat input compared to larger dendrites and spacing at high heat input. The extent of grain coarsening in the heat affected zone also increased with higher heat input. In conclusion, welding heat input significantly influences the properties of welded joints.
AN INTERDISCIPLINARY OPTIMIZATION APPROACH FOR CUTTING ATTRIBUTES OF LASER BE...indexPub
To improve and optimize the responses of a machining process, the choice of input machining control parameters is to be set at an optimal value.
As such one has to take up experimental methods, which are cumbersome, time-consuming, costly, and at times not feasible. During such situations,
optimization techniques like Genetic Algorithm (GA) can be used as they provide a cost-effective method for solving such complex problems.
"Scaling RAG Applications to serve millions of users", Kevin GoedeckeFwdays
How we managed to grow and scale a RAG application from zero to thousands of users in 7 months. Lessons from technical challenges around managing high load for LLMs, RAGs and Vector databases.
inQuba Webinar Mastering Customer Journey Management with Dr Graham HillLizaNolte
HERE IS YOUR WEBINAR CONTENT! 'Mastering Customer Journey Management with Dr. Graham Hill'. We hope you find the webinar recording both insightful and enjoyable.
In this webinar, we explored essential aspects of Customer Journey Management and personalization. Here’s a summary of the key insights and topics discussed:
Key Takeaways:
Understanding the Customer Journey: Dr. Hill emphasized the importance of mapping and understanding the complete customer journey to identify touchpoints and opportunities for improvement.
Personalization Strategies: We discussed how to leverage data and insights to create personalized experiences that resonate with customers.
Technology Integration: Insights were shared on how inQuba’s advanced technology can streamline customer interactions and drive operational efficiency.
Essentials of Automations: Exploring Attributes & Automation ParametersSafe Software
Building automations in FME Flow can save time, money, and help businesses scale by eliminating data silos and providing data to stakeholders in real-time. One essential component to orchestrating complex automations is the use of attributes & automation parameters (both formerly known as “keys”). In fact, it’s unlikely you’ll ever build an Automation without using these components, but what exactly are they?
Attributes & automation parameters enable the automation author to pass data values from one automation component to the next. During this webinar, our FME Flow Specialists will cover leveraging the three types of these output attributes & parameters in FME Flow: Event, Custom, and Automation. As a bonus, they’ll also be making use of the Split-Merge Block functionality.
You’ll leave this webinar with a better understanding of how to maximize the potential of automations by making use of attributes & automation parameters, with the ultimate goal of setting your enterprise integration workflows up on autopilot.
What is an RPA CoE? Session 2 – CoE RolesDianaGray10
In this session, we will review the players involved in the CoE and how each role impacts opportunities.
Topics covered:
• What roles are essential?
• What place in the automation journey does each role play?
Speaker:
Chris Bolin, Senior Intelligent Automation Architect Anika Systems
This talk will cover ScyllaDB Architecture from the cluster-level view and zoom in on data distribution and internal node architecture. In the process, we will learn the secret sauce used to get ScyllaDB's high availability and superior performance. We will also touch on the upcoming changes to ScyllaDB architecture, moving to strongly consistent metadata and tablets.
Introduction of Cybersecurity with OSS at Code Europe 2024Hiroshi SHIBATA
I develop the Ruby programming language, RubyGems, and Bundler, which are package managers for Ruby. Today, I will introduce how to enhance the security of your application using open-source software (OSS) examples from Ruby and RubyGems.
The first topic is CVE (Common Vulnerabilities and Exposures). I have published CVEs many times. But what exactly is a CVE? I'll provide a basic understanding of CVEs and explain how to detect and handle vulnerabilities in OSS.
Next, let's discuss package managers. Package managers play a critical role in the OSS ecosystem. I'll explain how to manage library dependencies in your application.
I'll share insights into how the Ruby and RubyGems core team works to keep our ecosystem safe. By the end of this talk, you'll have a better understanding of how to safeguard your code.
Northern Engraving | Modern Metal Trim, Nameplates and Appliance PanelsNorthern Engraving
What began over 115 years ago as a supplier of precision gauges to the automotive industry has evolved into being an industry leader in the manufacture of product branding, automotive cockpit trim and decorative appliance trim. Value-added services include in-house Design, Engineering, Program Management, Test Lab and Tool Shops.
The Department of Veteran Affairs (VA) invited Taylor Paschal, Knowledge & Information Management Consultant at Enterprise Knowledge, to speak at a Knowledge Management Lunch and Learn hosted on June 12, 2024. All Office of Administration staff were invited to attend and received professional development credit for participating in the voluntary event.
The objectives of the Lunch and Learn presentation were to:
- Review what KM ‘is’ and ‘isn’t’
- Understand the value of KM and the benefits of engaging
- Define and reflect on your “what’s in it for me?”
- Share actionable ways you can participate in Knowledge - - Capture & Transfer
"$10 thousand per minute of downtime: architecture, queues, streaming and fin...Fwdays
Direct losses from downtime in 1 minute = $5-$10 thousand dollars. Reputation is priceless.
As part of the talk, we will consider the architectural strategies necessary for the development of highly loaded fintech solutions. We will focus on using queues and streaming to efficiently work and manage large amounts of data in real-time and to minimize latency.
We will focus special attention on the architectural patterns used in the design of the fintech system, microservices and event-driven architecture, which ensure scalability, fault tolerance, and consistency of the entire system.
zkStudyClub - LatticeFold: A Lattice-based Folding Scheme and its Application...Alex Pruden
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Paper Link: https://eprint.iacr.org/2024/257
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📕 Detailed agenda:
Variables and Datatypes
Workflow Layouts
Arguments
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💻 Extra training through UiPath Academy:
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Speaker:
Chris Bolin, Senior Intelligent Automation Architect Anika Systems
1. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
393 | P a g e
Expert modeling and multi objective optimization of laser trepan
drilling of titanium alloy sheet
1
. Md Sarfaraz Alam*, 2
Md Tabish Haque
1,2,3
Motilal Nehru National Institute of Technology, Allahabad-211004, Uttar Pradesh, India
ABSTRACT
Nowadays laser machining became an
attractive machining process for difficult to cut
materials like ceramics, composites and super
alloys. Titanium alloys specially Ti-6Al-4V
(grade 5) is most widely used for different
technologically advanced industries due to their
superior performance characteristics such as
high strength and stiffness at elevated
temperatures, high strength to weight ratio,
high corrosion resistance, fatigue resistance, and
ability to withstand moderately high
temperatures without creeping. Laser trepan
drilling (LTD) being a thermal and non contact
nature and having the ability to produce micro
dimensions with required level of accuracy.
However laser drilled holes are inherently
associated with a number of defects like non
circularity of hole, spatter thickness and hole
taper. The present paper investigate the laser
trepan drilling(LTD) process performance
during trepanning of titanium alloy (Ti-6Al-4V)
by modeling and simultaneous optimization of
three important performance challenges such as
hole taper (HT), circularity at entrance
(CIRentry) and circularity at exit (CIRexit). A
hybrid approach of artificial neural network
(ANN)-genetic algorithm (GA) and grey
relational analysis (GRA) has been proposed for
multi-objective optimization. The verification
results are in the close agreements with the
optimization results.
Keywords: ANN, GA, GRA and LTD.
1. INTRODUCTION
The laser drilling process is one of the
most widely used thermal energy based non-
contact type advance machining process which can
be applied across a wide range of materials.
Nowadays laser drilling is finding increasingly
widespread application in the industries. Laser
beam machining is based on the conversion of
electrical energy into light energy and then into
thermal energy to remove the material from work
piece. The material removal process is by focusing
laser beam onto the work material for melting and
vaporizing the unwanted material to create a hole.
CO2 laser drilling has been widely used in
industries because of its high production rate and
abilities on rapidly varying holes size, drilling
holes at shallow angle, and drilling hard-to-work
material such as high strength materials, ceramic
and composite. Laser drilled holes are inherently
associated with a number of defects. Non
circularity of hole, spatter thickness, and hole taper
are some defects associated with laser drilling. As a
result, the quality of the drilled holes is the main
issue in the laser drilling process. There are two
types of laser drilling: trepan drilling and
percussion drilling. Trepan drilling involves cutting
around the circumference of the hole to be
generated, whereas percussion drilling is carried
out by utilizing a focused laser spot to heat, melt
and vaporize the target material such that a desired
hole is formed through the work piece with no
relative movement of the laser or work material
[1,2]. Fig. 1 shows a schematic of laser beam
drilling [2]
Fig. 1: Schematic of laser beam drilling
2. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
394 | P a g e
A Number of researchers have performed the
experimental studies to investigate into the process
of laser percussion drilling by considering some
significantly affecting factors/ process parameters,
without applying any scientifically designed
experimentation technique, further analyzing the
impact of every parameter on observed process
performance characteristics. Tongyu and Guoquan,
[3] performed a study to investigate the relationship
of laser beam parameters (energy, power, pulse
width, pulse frequency) with the hole geometrical
quality characteristics and to find feasibility of high
carbon steel to investigate the heat affected zone in
laser drilling. Laser percussion drilling of alumina
ceramics was investigated by Kacar et al, [4] to
determine the effect of peak power (2-11 kw) and
pulse duration (0.5-7 ms) on geometrical features
of drilled holes such as diameter at entrance and
exit, crater (Initial cavity before getting through
hole) diameter and hole taper angle. The crater
diameter and the hole exit diameters shows
proportional changes with the Pulse duration and
peak power, although, the entrance hole diameter
do not changes much with them. The reason they
found, after morphological investigation with the
help of optical microscope that the resolidified
material at the entrance side increases with the
increase in pulse duration and peak power, which
ultimately reduces the entrance hole diameter even
after larger crater diameter. Also due to the same
reason there is a decrease in taper angle at the same
conditions, which further becomes negative for
higher values of process parameters. Ghoreishi et
al. [5] investigated the relationships and parameter
interactions between laser peak power, laser pulse
width, pulse frequency, number of pulses, assist
gas pressure and focal plane position on the hole
taper and circularity in laser percussion drilling of
stainless steel and mild steel. The central composite
design was employed to plan the experiments in
order to obtain required information. The process
performance was evaluated in terms of equivalent
entrance diameter, hole taper and hole entrance
circularity. They found that the pulse frequency
had a significant effect on the hole entrance
diameter and hole circularity in drilling stainless
steel unlike the drilling of mild steel, where the
pulse frequency had no significant effect on the
hole characteristics. Benyounis and Olabi [6] did a
comprehensive literature review of the applications
of design of experiments, evolutionary algorithms
and computational networks on the optimization of
different welding processes through mathematical
models. According to their review of various
literatures, they were of the opinion that there was
considerable interest among the researchers in the
adaption of response surface methodology (RSM)
and artificial neural net- work (ANN) to predict
responses in the welding process. For a smaller
number of experimental runs, they noted that RSM
was better than ANN and genetic algorithm (GA)
in the case of low order non-linear behavior of the
response data. In the case of highly non-linear
behavior of the response data, ANN was better than
other techniques. They also observed that the
Taguchi approach of S/N ratio might lead to non-
optimal solutions with less flexibility and the
conducting of needless experiments. Some recent
attempts have been made to control the laser drilled
hole taper through the development of drilling
techniques [7, 8]. Ng and Li [9] assessed the effect
of laser peak power and pulse width on the hole
geometry repeatability in Nd:YAG laser percussion
drilling of 2 mm thick mild steel sheets. Thirty-five
holes were drilled and analyzed for each set of
identical laser parameters. They found that higher
peak power and shorter pulse width gave better
hole geometry repeatability. The circularity of the
entrance hole ranged from 0.94 to 0.87, and was
found to correlate with repeatability.
Titanium and its alloys are most widely
used for different technologically advanced
industries such as aerospace, marine, chemical,
food processing and medical due to their superior
performance characteristics such as high strength
and stiffness at elevated temperatures, high strength
to weight ratio, high corrosion resistance, fatigue
resistance, and ability to withstand moderately high
temperatures without creeping [10]. The Ti-6Al-4V
is an alloy (grade 5) of Ti, has extensively used in
aerospace, marine, chemical processing, medical
and automobile sectors for making different
components such as airframes, fastener
components, vessels, cases, hubs, forgings, bone
plates, rods, expendable ribs cages, finger and toe
replacements, spinal fusion cages and dental
implants, pistons and piston rings. Ti and its alloys
cannot be cut easily by conventional cutting
methods due to their improved mechanical
properties, poor thermal conductivity, low elastic
modulus and high chemical affinity at elevated
temperatures. Due to the poor thermal conductivity
of these alloys, the heat generated during the
cutting cannot dissipated properly which results
very high temperature at the tool–work piece
interface and melting of the tool tip. Thus adversely
affects the tool life. Ti is chemically reactive at
elevated temperatures due to which the tool
material either rapidly dissolves or chemically
reacts during the cutting process, resulting
premature tool life [11]. The low elastic modulus of
Ti alloys permits greater deflection of workpiece
during machining and complexity of the machining
increases. While machining the Ti alloys, the
contact length between the tool and chip has been
found very small due to which high cutting
temperatures and high cutting stresses are
concentrated near the tool tip which results the
melting of tool tip and finally tool life reduces. Due
to the thermal plastic instability, the shear strains in
3. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
395 | P a g e
the chips are not uniform which promotes the
formation of serrated chips. These serrated chips
create fluctuations in the cutting force (generates
vibrational forces) which are responsible for sever
flank wear of cutting tools [12]. Thus there is a
crucial need for reliable and effective cutting
process for Ti and its alloys. Alternatively for the
cutting of these materials advanced cutting
processes such as Electric discharge machining,
ultrasonic machining, laser beam machining may
be used with some limitations. But for using these
advanced cutting methods, a lot of research work
has been required so that the required objectives
may be fulfilled by controlling different process
parameters.
Most of the previous works related to hole
drilling used the percussion drilling process where
with intense laser burst, the hole size was the size
of the beam that was varied by focusing. The
present study focuses on the alternative trepan
drilling. This paper reports the multi-objective
optimization of hole geometrical qualities such as
HT, CIRentry and CIRexit in the pulsed Nd:YAG
laser trepanning of Titanium alloy sheet. The
motivation for the investigation is the fact that
Titanium alloys being increasingly used in different
industries and engineers of these industries are
trying to obtain best qualities of these materials in
the laser drilling. In this investigation, Ti-6Al-4V
(Titanium alloy sheet grade 5) sheet has been
selected because it is known for its exceptional
performance characteristics and is one of the
mostly used Titanium alloys. Due to higher
material costs, the Ti alloys require such type of
drilling methods in which minimum wastage of
materials is obtained with satisfactory trepanned
qualities. But the reported research works show
that poor qualities are obtained by use of air or
nitrogen assist gases due to low thermal
conductivity and high chemical reactivity at
elevated temperatures. The use of costlier inert
gases may further increase the cutting cost.
Therefore, the aim of present research is to obtain
good quality of trepanned hole by using N2 as assist
gas. ANN has been applied for the modeling of HT,
CIRentry and CIRexit with the help of data obtained
by the L27 orthogonal array experimentation. The
hybrid approach of ANN, GA and GRA based
entropy measurement technique has been applied
for modeling and multi-objective optimization of
HT, CIRentry and CIRexit. The predicted optimum
results have been verified by confirmation tests.
2. EXPERIMENTAL SETUP AND DESIGN
OF EXPERIMENTS
The experiments have been performed on
200W pulsed Nd:YAG laser cutting system with
CNC work table supplied by SIL Pune, India. The
assist gas used is Nitrogen and it is passed through
a nozzle of 1 mm diameter, which remains constant
throughout the experiments. The focal length of the
lens is 50 mm and the standoff distance is 1 mm.
The Titanium alloy sheet (Ti-6Al-4V) of thickness
1.4 mm is used as work material. The chemical
compositions of the Ti-6Al-4V are shown in Table
1. Pulse width or pulse duration, pulse frequency,
assist gas pressure and cutting speed have been
selected as input process parameters (control
factors). An exhaustive pilot experimentation has
been performed in order to decide the range of each
control factors for complete through cutting. The
different control factors and their levels are shown
in Table 2. The quality characteristics or responses
selected for the analyses are HT, CIRentry and
CIRexit. 1 mm diameter holes are made with two
repetitions for the each experimental run. The hole
diameters at the entrance and exit were measured at
six orientations at an interval of 300
. Diameters are
measured by using optical microscope with 10X
magnification supplied by Radical instruments,
India. The HT, CIRentry and CIRexit were calculated
by following formula:
Hole taper
t
dd exitfentrancef
,
(Since α =tan α, for small value of α) Where
(df) entrance and (df) exit are mean Feret’s diameters at
the entrance and exit, respectively and (t) is the
drilled hole depth.
Circularity at entry/exit
where (df) Min and (df) Max are minimum and
maximum Feret’s diameters at entrance or exit side
of drilled hole.
The total number of experiments can be
substantially reduced with the help of a well
designed experimental plan without affecting the
accuracy during the experimental study of any
manufacturing process. Taguchi have suggested
that it is better to make the process robust rather
than equipments and machinery just by nullifying
the effects of variations through selection of
appropriate parameter level. Taguchi has suggested
properly designed experimental matrices known as
orthogonal arrays (OAs) to conducts the
experiments. In this present research work four
control factors with three levels of each have been
considered. Hence experiments can be performed
4. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
396 | P a g e
by using simplest L9 OA. But authors have selected L27 OA for high resolution factor [13].
Table 1: Composition of titanium alloy sheet (grade-5) (% volume)
Table 2: Control factors and their levels
3. METHODOLOGY
3.1. ARTIFICIAL NEURAL NETWORK (ANN)
ANN is information processing paradigm
inspired by biological nervous systems like our
brain. In neural network a large number of highly
interconnected processing elements (neurons) are
working together. Like people, they learn from
experience. In a biological system, learning
involves adjustments to the synaptic connections
between neurons; the same is true for ANNs [14].
In the network, each neuron receives total input
from all of the neurons in the preceding layer as
(1)
Where the total or net input and N is
are the numbers of inputs to the rth neuron in the
forward layer. is the weight of the connection
to the qth neuron in the forward layer from the rth
neuron in the preceding layer , is the input
from the rth neuron in the preceding layer to the
forward layer and the bias to qth neuron . A
neuron in the network produces its output ( )
by processing the net input through an activation
function Ғ , such as log sigmoid function and pure
linear function chosen in this study as below
(2)
&
(3)
In calculation of connection weights, often
known as network training, the weights are given
quasi-random initial values. They are then
iteratively updated until converges to the certain
value using the gradient descent method. Gradient
descent method updates weights so as to minimize
the mean square error between the network output
and the training data set. For simultaneous
optimization of more than one quality
characteristics, sometimes it is desirable to
normalize the quality characteristics. So the
training data set, i.e. the experimental values of
quality characteristics have been normalized using
following formula:
(4)
Where the normalized value of the kth
response is during ith observation, is the
maximum value of for the kth response.
3.2. GENETIC ALGORITHM (GA) FOR
OPTIMIZATION
Genetic algorithms (GA) are the global
optimization technique which is quite suitable for
non-linear optimization problems. GA is based on
the Darwin’s principle of “survival of fittest” .The
algorithm starts with the creation of random
population. The individual with best fitness are
selected to form the mating pair and then the new
population is created through the process of cross-
over and mutation. The new individuals are again
tested for their fitness and this cycle is repeated
until some termination criteria are satisfied [14].
3.3 GREY RELATIONAL ANALYSIS (GRA)
A common difficulty with multi-objective
optimization is the appearance of an objective
conflict; none of the feasible solution allows
simultaneous optimal solution for all objectives.
The individual optimal solutions of each objective
are usually different. To get the solution of multi-
objective optimization problem, using classical
methods, all the objectives are converted into
single objective function. There are many methods
of transforming multi-objective optimization
problem into single objective optimization problem
and objective weighting method is one of the
popular methods. In objective weighting method,
multi-objective functions are combined into one
overall objective function by assigning different
weigh to different objective [15]. The
determination of weight is a critical aspect, which
sometimes is decided by designer’s experience or
some mathematical techniques. In this study, the
GRA coupled with entropy measurement technique
[16] has been used to find the weight of each
quality characteristics for multi-objective
Al Fe Sn V Ti
6.22 0.187 0.56 3.35 89.6
Symbol Factors Level 1 Level 2 Level 3
X1 Pulse width (ms) 0.8 1.2 1.6
X2 Pulse frequency (Hz) 13 17 21
X3 Gas pressure (kg/cm2
) 6 8 10
X4 Trepanning speed (mm/s) 0.1 0.2 0.3
5. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
397 | P a g e
optimization. The working of the GRA and entropy
measurement technique has been explained with
the help of block diagram in Fig. 2.
Fig. 2: Block diagram for GRA and Entropy measurement technique
The normalized value of the quality characteristics have been calculated using Eqs. (4), and have been shown in
the Fig.3.
4. MODELING
The optimal neural network architecture
used for normalized hole taper (NHT), normalized
circularity at entry (NCIRentry) and normalized
circularity at exit (NCIRexit) is shown in Fig. 4. The
network for all three NHT, NCIRentry and NCIRexit
consists of one input, one hidden and one output
layer. The input and output layers have four and
one neuron respectively. The neurons in input layer
are corresponded to Pulse width, Pulse frequency,
Gas pressure and Trepanning speed. Output layer
corresponds to NHT, NCIRentry and NCIRexit. The
hidden layer has five neurons in case of all. The
activation function used for the hidden layer and
output layer was log sigmoid and pure linear
respectively. In this work, a commercially available
software package MATLAB was used for the
training of ANN .The values of the weights, and
biases, after network getting fully trained are
shown in the Table 3 for all the NHT, NCIRentry and
NCIRexit.
0
0.2
0.4
0.6
0.8
1
1.2
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Normalizedvalues
Experiment Number
Experimental values for NHT
Experimental values for
NCIRentry
Experimental values for
NCIRexit
Input layer
Hidden layer
X1
X2
X3
X4
Output layer
wqr bq
NHT/ NCIRentry/
NCIRexit
Normalization of
data
Calculation of grey
relational coefficient
Calculation of the sum of the
grey relational coefficient
Evaluation of the
normalized coefficient
Calculation of the entropy of
each quality characteristics
Calculation of the sum
of entropy
Calculation of the weight of
each quality characteristic
Fig. 4: Architecture of artificial neural network for NHT, NCIRentry
and NCIRexit
Fig. 3: Normalized values of quality characteristics
6. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
398 | P a g e
Table 3: Final values of Weights and Biases for NHT, NCIRentry and NCIRexit
So, in the mathematical form, the ANN model for
NMRR can be represented as follows:
NHT/NCIRentry/NCIRexit (5)
Where and corresponded to weight and
bias to output layer and is the net input to the
output layer from hidden layer and it is given by,
q=1, 2… 5
The results of the experimental data and neural
network predicted data for NHT, NCIRentry and
NCIRexit have been compared in the Table 4. It is
evident that ANN prediction is in good agreement
with the experimental results. It is found that ANN
with mean square error of 0.000037%, 0.0000186%
and 0.000125% respectively, appears to constitute
a workable model for predicting the characteristics
under given set of input parameters for LTD.
The values of , , and are shown in Table 3.
I: Experiment No. II: Pulse width III: Pulse frequency IV: Gas pressure
V: Trepanning speed VI: Experimental Hole taper VII: Experimental Circularity VIII:
Experimental Circularity
at entry at exit
IX: ANN predicted Hole taper X: ANN predicted Circularity XI: ANN predicted Circularity XII: % error
in prediction of
at entry at exit Hole taper
XIII: % error in prediction of XIV: % error in prediction of
Circularity at entry Circularity at exit
Table 4: Comparison of ANN predicted result with the experimental result for NHT, NCIRentry and NCIRexit
I II III IV V VI VII VIII IX X XI XII XIII XIV
1 0.500 0.619 0.600 0.333 0.433 0.914 0.966 0.433 0.914 0.952 0.055 0.005 1.468
2 0.500 0.619 0.800 0.667 0.736 0.927 0.942 0.736 0.927 0.952 0.051 0.005 1.096
3 0.500 0.619 1.000 1.000 0.992 0.973 0.963 0.991 0.973 0.961 0.027 0.004 0.150
4 0.500 0.810 0.600 0.667 0.539 0.902 0.970 0.539 0.902 0.971 0.079 0.003 0.100
5 0.500 0.810 0.800 1.000 0.691 0.910 0.955 0.691 0.910 0.955 0.049 0.004 0.033
Weights to hidden layer from
input layer
Bias to
hidden
layer
Weights to output layer
Bias to
output
layer
NHT [122.7035 -28.3073 16.9694 -
33.6773;
-4.8487 -22.6453 -32.7136 -
10.3398;
2.8113 -2.9929 5.8978 0.53677;
3.9119 3.3126 0.68229 0.29932;
-2.7571 2.4243 -5.7577 -0.61036]
[-
81.9011;
58.7437;
-1.1352;
-4.0345;
0.56399]
[0.33548 -0.44801 -43.5783 -2.3246 -
105.1382]
[46.4105
]
NCIRentry [-3.0176 -4.1509 60.4266 -
0.77578;
1.0815 6.3481 1.2684 1.7164;
-1.1774 -6.0712 -1.3746 -1.6547;
41.2793 -1.1825 8.5567 -34.2151;
5.5617 -56.9911 1.8769 2.2187]
[-
29.6378;
-8.1871;
8.1269;
-3.1741;
51.2141]
[-0.094972 -4.8731 -5.0107 -0.046963 -
0.074669]
[6.129]
NCIRexit [19.7725 6.0393 -7.3166 -1.7965;
0.26041 67.3029 -70.1356
78.0474; -45.1386
185.994 64.4417 66.0488;
-57.4946 0.24336 0.11946 -
0.53196;
20.0861 -59.1983 24.6627 -
61.9418]
[-13.606;
-9.8892;
-225.056;
64.2284;
64.7269]
[-0.074678 0.047406 -0.045112 -66.1898 -
0.048632]
[67.1431
]
7. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
399 | P a g e
6 0.500 0.810 1.000 0.333 0.584 0.914 0.935 0.584 0.914 0.935 0.001 0.095 0.004
7 0.500 1.000 0.600 1.000 1.000 0.971 0.954 1.000 0.971 0.954 0.000 0.002 0.043
8 0.500 1.000 0.800 0.333 0.703 0.902 0.904 0.704 0.902 0.906 0.038 0.001 0.201
9 0.500 1.000 1.000 0.667 0.900 0.942 0.942 0.899 0.942 0.943 0.043 0.003 0.055
10 0.750 0.619 0.600 0.667 0.337 0.935 0.927 0.338 0.935 0.926 0.015 0.003 0.132
11 0.750 0.619 0.800 1.000 0.372 0.956 0.960 0.371 0.956 0.961 0.116 0.000 0.121
12 0.750 0.619 1.000 0.333 0.437 0.957 0.901 0.437 0.958 0.901 0.002 0.069 0.001
13 0.750 0.810 0.600 1.000 0.437 0.952 0.962 0.436 0.952 0.964 0.181 0.006 0.117
14 0.750 0.810 0.800 0.333 0.293 0.919 0.919 0.292 0.918 0.921 0.398 0.113 0.176
15 0.750 0.810 1.000 0.667 0.670 0.944 0.921 0.670 0.943 0.922 0.067 0.110 0.120
16 0.750 1.000 0.600 0.333 0.555 0.937 0.884 0.555 0.937 0.884 0.038 0.002 0.003
17 0.750 1.000 0.800 0.667 0.696 0.925 0.902 0.696 0.925 0.901 0.011 0.002 0.160
18 0.750 1.000 1.000 1.000 0.668 0.985 0.946 0.669 0.985 0.945 0.165 0.001 0.105
19 1.000 0.619 0.600 1.000 0.335 0.974 1.000 0.335 0.974 0.999 0.009 0.006 0.090
20 1.000 0.619 0.800 0.333 0.517 0.961 0.947 0.518 0.960 0.947 0.179 0.061 0.001
21 1.000 0.619 1.000 0.667 0.710 1.000 0.979 0.710 1.000 0.978 0.021 0.000 0.094
22 1.000 0.810 0.600 0.333 0.513 0.969 0.949 0.514 0.969 0.949 0.222 0.002 0.049
23 1.000 0.810 0.800 0.667 0.526 0.946 0.960 0.526 0.947 0.962 0.093 0.124 0.267
24 1.000 0.810 1.000 1.000 0.834 0.980 0.967 0.834 0.980 0.968 0.006 0.010 0.100
25 1.000 1.000 0.600 0.667 0.656 0.991 0.986 0.656 0.991 0.986 0.007 0.000 0.015
26 1.000 1.000 0.800 1.000 0.664 0.970 0.978 0.665 0.971 0.977 0.107 0.009 0.069
27 1.000 1.000 1.000 0.333 0.914 0.977 0.904 0.913 0.977 0.903 0.186 0.003 0.152
5. MULTI OBJECTIVE OPTIMIZATION
Using GRA coupled with entropy
measurement, the weight for NHT, NCIRentry and
NCIRexit have been found as 0.33, 0.33 and 0.34
respectively. Now the multi-objective optimization
problem can be transformed into single objective
optimization problem. In the present case, both the
objective functions are of conflicting nature
because the aim is to maximize HT the and
minimize the NCIRentry, NCIRexit. Thus, the
objective function of optimization problem can be
stated as below:
Find: X1, X2, X3 and X4
Minimize:
(6)
Where = 0.33, 0.33 and = 0.34 NHT,
NCIRentry and NCIRexit Eq. (5) ,with range of
process input parameters:
0.8≤ ≤1.6
13≤ ≤21
6≤ ≤10
0.1≤ ≤0.3
The critical parameters of GA are the size
of the population, cross-over rate, mutation rate,
and number of generations. After trying different
combinations of GA parameters, the population
size 20, cross-over rate 0.8, mutation rate 0.01 and
number of generation 40, have been taken in the
present study. The objective function in Eq. (6) has
been solved without any constraint. The
generation-fitness graphics have been shown in the
Fig.5. The fitness function is optimized when the
mean curve converges to the best curve after 7
generation. The corresponding values of Pulse
width, Pulse frequency, Gas pressure and
Trepanning speed have been found as1.3 ms, 17
Hz, 8 kg/cm2
and 0.2 mm/s.
8. Md Sarfaraz Alam, Md Tabish Haque / International Journal of Engineering Research and
Applications (IJERA) ISSN: 2248-9622 www.ijera.com
Vol. 3, Issue 3, May-Jun 2013, pp.393-401
400 | P a g e
Fig. 5: The generation-fitness graphics
6. DISCUSSION
Achieving a good compromise between
objective functions in multi-objective optimization
problem is a big challenge due to existence of
multiple solutions, known as Pareto-optimal
solutions. To overcome it, in the present work,
weights for each quality characteristics have been
calculated first, to get optimal solution.
7. CONCLUSIONS
The multi-objective optimization of laser
trepan drilling of Ti-6Al-4V using hybrid approach
of artificial neural network, genetic algorithm and
grey relational analysis with entropy measurement
technique has been done. Following conclusions
have been drawn on the basis of results obtained:
(1) The developed models for HT, CIRentry and
CIRexit, with mean square error of 0.000037%,
0.0000186% and 0.000125% respectively, are well
in agreement with the experimental result.
(2) The optimum levels of control factors are Pulse
width, Pulse frequency, Gas pressure and
Trepanning speed have been found as 1.3 ms, 17
Hz, 8 kg/cm2
and 0.2 mm/s respectively.
(3) Validation has been performed in order to
verify the result, which shows a good agreement
between the optimized and experimental result.
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