This document presents an experimental study to optimize the wire electrical discharge machining (WEDM) process parameters for machining EN47 spring steel based on minimizing surface roughness. Experiments were conducted using an L27 orthogonal array with four process parameters (pulse on time, pulse off time, wire feed rate, and gap voltage) at three levels. The optimal combination found was the highest levels of pulse on time and pulse off time along with the lower level of wire feed and gap voltage. Analysis of variance showed pulse on time and wire feed rate had the most significant influence on surface roughness. A confirmation test found roughness was reduced by 26% from the initial to optimal conditions.
EFFECT OF PROCESS PARAMETERS ON SURFACE ROUGHNESS OF NICKEL BASED ALLOYS IN WEDMijmech
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In contrast to conventional machining process, WEDM may be proved more economic and efficient in
precise machining of wide range of materials ranging from die steel to the high temperature resistance
super alloys. In this study, the effect of WEDM process parameters like peak current (Ip), pulse on time
(Ton), pulse off time (Toff) and servo voltage (V) on the surface roughness has been considered while
machining of Nimonic 90 and Monel 400 using Taguchiâs method. Using Taguchiâs L18 orthogonal array,
process parameters were investigated for surface roughness. Analysis of variance shows that Ton and Ip
are highly significant process parameters for surface roughness.
The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company â Egypt to perform the experimental work, and the tools were offered by Flowdrill Company â Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.
This research was a part of my Dual Degree Thesis and presented at The Minerals Metals and Materials Society Annual Meeting and Conference held at Seattle, WA in 2010.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
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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 AssessmentâŠ. And many more.
Evaluation of Optimal Parameters for Surface Roughness Using Single Objective...IJERA Editor
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Medium carbon steel EN8 has a wide variety of applications in oil, gas and tool industries. It is most commonly
used where high tensile strength is required. In the present work, an attempt has been made to explore the effect
of machining parameters on Surface Roughness (Ra). Taguchiâs single objective optimization technique is used
to optimize the machining parameters in EDM for EN8 steel. For the experimentation Taguchiâs L27
Orthogonal array has been used. The input parameters selected are Pulse on time (PON), Pulse off time (POFF),
Wire tension (WT) and Wire feed (WF). From the Taguchi results, optimal combination of machining
parameters for Surface Roughness is found at Pulse-on time (PON) level 3(131ÎŒs), Pulse-off time (POFF) level 2
(58ÎŒs), Wire tension (WT) level 1(2 Kg-f) and Wire feed rate (WF) level 1(4m/min). ANOVA was used to find
the influence of machining parameters on Surface Roughness. From the results, it is found that wire feed rate
(WF) has high influence (F = 47.16) and Pulse-off time (TOFF) has very low influence (F = 1.57) in effecting the
Surface Roughness. Regression model for Surface Roughness has been prepared by using MINITAB-16
software. Experimental values and Regression values of Surface Roughness were compared and from the graph,
it is clear that both the values are very close to each other. Hence, Regression model prepared is accurate,
adequate and it can be used for the prediction of Surface Roughness.
EFFECT OF PROCESS PARAMETERS ON SURFACE ROUGHNESS OF NICKEL BASED ALLOYS IN WEDMijmech
Â
In contrast to conventional machining process, WEDM may be proved more economic and efficient in
precise machining of wide range of materials ranging from die steel to the high temperature resistance
super alloys. In this study, the effect of WEDM process parameters like peak current (Ip), pulse on time
(Ton), pulse off time (Toff) and servo voltage (V) on the surface roughness has been considered while
machining of Nimonic 90 and Monel 400 using Taguchiâs method. Using Taguchiâs L18 orthogonal array,
process parameters were investigated for surface roughness. Analysis of variance shows that Ton and Ip
are highly significant process parameters for surface roughness.
The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company â Egypt to perform the experimental work, and the tools were offered by Flowdrill Company â Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.
This research was a part of my Dual Degree Thesis and presented at The Minerals Metals and Materials Society Annual Meeting and Conference held at Seattle, WA in 2010.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
Â
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 AssessmentâŠ. And many more.
Evaluation of Optimal Parameters for Surface Roughness Using Single Objective...IJERA Editor
Â
Medium carbon steel EN8 has a wide variety of applications in oil, gas and tool industries. It is most commonly
used where high tensile strength is required. In the present work, an attempt has been made to explore the effect
of machining parameters on Surface Roughness (Ra). Taguchiâs single objective optimization technique is used
to optimize the machining parameters in EDM for EN8 steel. For the experimentation Taguchiâs L27
Orthogonal array has been used. The input parameters selected are Pulse on time (PON), Pulse off time (POFF),
Wire tension (WT) and Wire feed (WF). From the Taguchi results, optimal combination of machining
parameters for Surface Roughness is found at Pulse-on time (PON) level 3(131ÎŒs), Pulse-off time (POFF) level 2
(58ÎŒs), Wire tension (WT) level 1(2 Kg-f) and Wire feed rate (WF) level 1(4m/min). ANOVA was used to find
the influence of machining parameters on Surface Roughness. From the results, it is found that wire feed rate
(WF) has high influence (F = 47.16) and Pulse-off time (TOFF) has very low influence (F = 1.57) in effecting the
Surface Roughness. Regression model for Surface Roughness has been prepared by using MINITAB-16
software. Experimental values and Regression values of Surface Roughness were compared and from the graph,
it is clear that both the values are very close to each other. Hence, Regression model prepared is accurate,
adequate and it can be used for the prediction of Surface Roughness.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
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The purpose of this research work is to determine the optimal cutting condition of EDM process of different
work piece materials using different compositions of Cu-W tool Electrodes. The key cutting factors such as
Discharge Current, Voltage, Pulse- On â Time, Duty Cycle, Spark Gap and flushing pressure will be optimized.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
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Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950âs and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
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Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
PARAMETER OPTIMIZATION IN VERTICAL MACHINING CENTER CNC FOR EN45 (STEEL ALLOY...IAEME Publication
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Now days optimal machining parameters are of great concern in manufacturing environments, where economy of machining operations plays a key role in competitiveness in the market. This paper aims at developing a statistical model to optimize the surface parameters such as material removal rate (MRR) and surface roughness (SR).Response Surface Methodology (RSM) experimental design was used for conducting experiment. The experimental study was carried out in a CNC vertical machining center. The work piece material was EN45 (steel alloy).EN45 is widely used in the motor vehicle industry for leaf springs, truncated conical springs, helical springs and many general applications.
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
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Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
Â
The purpose of this research work is to determine the optimal cutting condition of EDM process of different
work piece materials using different compositions of Cu-W tool Electrodes. The key cutting factors such as
Discharge Current, Voltage, Pulse- On â Time, Duty Cycle, Spark Gap and flushing pressure will be optimized.
Experimental Investigations to Study the Impact of Machining Parameters on Mi...IJERA Editor
Â
Plasma arc cutting is extensively used to cut steels and aluminum. Plasma arc cutting was invented in 1950âs and since then, it became commercial on its advent into the industry. The purpose of this research is to ascertain the influence of various parameters on plasma arc cutting process while machining mild steel. The experiments were conducted using Taguchi L16 orthogonal array with current, voltage, speed, plate thickness as the control parameters and surface roughness, kerf as the response variables. The optimal parameter setting for the machining process is determined by conducting a Grey-Taguchi method. Orthogonal array L16 (4 power 4) of Taguchi, Signal to Noise ratio, the Analysis of Variance(ANOVA) are employed to find the optimal levels and to analyze the optimum levels and to analyze the impact of current, voltage, speed, plate thickness on kerf and surface roughness.
Investigation of Process Parameters for Optimization of Surface Roughness in ...IJERA Editor
Â
Surface roughness has significant effect on functionality and service life of components. If surface roughness is properly controlled then, performance of the component enhances in operational applications. Surface roughness becomes key concern when intricate profiles and shapes are required to be manufactured in components. The objective of the paper is to bring up an adequate surface roughness in finish cut by optimizing process variables. If initial surface form is obtained by proper control of machining parameters then additional finishing efforts and lead time reduce a lot. In the industrial tool room survey availability of machining data is prime concern in terms of tuned process parameter for precision machining. Optimization of process parameters is essential in order to arrest surface roughness and thereby improve surface textures. Experimental investigations are performed to study the effect of pulse current, pulse on time and gap voltage on response of surface roughness, in case of ram EDM. Design of experimentation (DOE) and ANOVA are carried out for optimization of process parameters, within work interval of finish cut machining
PARAMETER OPTIMIZATION IN VERTICAL MACHINING CENTER CNC FOR EN45 (STEEL ALLOY...IAEME Publication
Â
Now days optimal machining parameters are of great concern in manufacturing environments, where economy of machining operations plays a key role in competitiveness in the market. This paper aims at developing a statistical model to optimize the surface parameters such as material removal rate (MRR) and surface roughness (SR).Response Surface Methodology (RSM) experimental design was used for conducting experiment. The experimental study was carried out in a CNC vertical machining center. The work piece material was EN45 (steel alloy).EN45 is widely used in the motor vehicle industry for leaf springs, truncated conical springs, helical springs and many general applications.
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Â
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Optimization of Weld Bead Geometry in Submerged Arc Welds Deposited On En24 S...iosrjce
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IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
OPTIMIZATION OF MACHINING PARAMETERS IN EDM OF CFRP COMPOSITE USING TAGUCHI T...IAEME Publication
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Electrical discharge machining (EDM) is a nontraditional manufacturing technique that has been widely used in the production of tools and dies throughout the world in recent years. The most important performance measure in EDM is the surface roughness. In this study, the effect and
optimization of machining parameters on surface roughness in an EDM operation was investigated by using the Taguchi method. The experimental studies were conducted under varying gap voltage,discharge current, and pulse-on time
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
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Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
This paper details the application of Taguchi
techniques to determine the optimal process parameters for
submerged arc welding (SAW).The planned experiment work is
conducted in the semiautomatic submerged arc welding machine
and signal to noise ratios have been computed .the contribution of
each factor has been validated by analysis of variance(ANOVA).
The results of the present investigation indicate that the welding
voltage is the most significant parameter that controls the bead
penetration as compared to other controlling parameters. The
contribution of voltage, current welding speed and nozzle-to-plate
distance have been found to be respectively: 60.8%, 9.86%,
3.54% and 13.8%. Optimum results have been obtained by using
26v, 475A at a trolley speed of 0.25 m/min and NPD of 16 mm.
Process Parameter Optimization of WEDM for AISI M2 & AISI H13 by Anova & Anal...IJERA Editor
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WEDM is a widely recognized unconventional material cutting process used to manufacture components with complex shapes and profiles of hard materials. In this thermal erosion process, there is no physical contact between the wire tool and work materials. AISI M2 and AISI H13 materials are taken for studyand molybdenum wire electrode diameter (0.18mm); experiment is conducted according to Taguchiâs L16 OA, with input parameters as Peak current, Pulse on, Pulse off their response on MRR, Surface Roughness, Kerf width & Spark Gap is analysed to check the significance of each using ANOVA. Process parameter optimization is done by Analytic Hierarchy Process with the criteria Maximum MRR, minimum kerf and surface roughness. It is observed that for material AISI M2 at low value of peak current (1 A), pulse off (20ÎŒs) and pulse on (30ÎŒs) we can minimize surface roughness (3.30ÎŒm), kerf width (0.195 mm) and maximize MRR (0.022 g/min),from the selected levels whereas for material AISI H13 Peak current (1A), Pulse On (40ÎŒs) and high Pulse Off (30ÎŒs) we get better Surface roughness (3.71 ÎŒm), kerf width (0.196mm) and maximum MRR (0.020g/min), from the selected levels.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
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A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9”s (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13”s (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1”in for surface roughness and 0.024Âș for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
Â
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 34 (=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9ÎŒs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13ÎŒs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1ÎŒin for surface roughness and 0.024Âș for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR...meijjournal
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Wire electrical discharge machining (WEDM) is a non conventional machining process which is widely used in machining of conductive materials.The applications of WEDM are in automobiles, aero-space, medical instruments, tool and die industries. in the present study analysis of effect of various control factors like Ton,Toff,Sv,Ip,Wf,Wt on checking the cutting rate of S7 steel is studied by using wire cut EDM and one factor time approach.S7 steels contain less carbon and higher toughness than the high carbon types that are more wear resistant. Shock resistant steels are used where heavy cutting or forming operations is required and chipping or breakage of high-carbon wear-resistant steels is a problem. The other big advantage of this study is to select the range of significant control factors for final experimentation.
International Journal of Engineering Research and DevelopmentIJERD Editor
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Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
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The present paper is on the analysis of surface roughness characteristics Ra, Rq and Rz during the machining of
medium carbon steel EN19. The experiments have been done under dry environment by using a coated carbide
tool. For the optimization of process parameters Taguchi based Grey Relational Grade method was used.
Taguchiâs standard L9 Orthogonal Array was used for conducting the experiments. From the Grey analysis,
optimal parametric combination for multi-responses (Ra, Rq and Rz) was found at cutting speed: 225 mm/min,
feed: 0.05 mm/rev and depth of cut: 0.4 mm respectively. Analysis of variance (ANOVA) was used for analyse
the influence of process parameters on multi responses. From the analysis it is concluded that, speed has high
influence (F= 34.18, P= 0.025<0.05)>0.05). Regression models were developed for Ra, Rq and Rz, which are
very significant parameters from contact stiffness, fatigue strength and surface wear point of view. The models
prepared were highly significant because they have high coefficient of correlation values (R2 =0.992, 0.987 and
0.982 for Ra, Rq and Rz respectively). Hence, the models can be used for accurate prediction of surface
roughness characteristics.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
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The term steel is used for many different alloys of iron. All steels cover small amounts of carbon and manganese. There do exist many types of steels which are(among others) plain carbon steel, stainless steel, alloysteel and tool steel. Carbon steel is the most extensively used kind of steel. The properties of carbon steel depend mainly on the amount of carbon it contains. Maximum carbon steel has a carbon content of less than 1%. Carbon steel is made into an extensive range of products, including structural beams, car bodies. In fact, there are 3 types of plain carbon steel namely low carbon steel, medium carbon steel, high carbon steel. It is good to exact that plain carbon steel is a type of steel having a maximum carbon content of 1.5% along with small percentages of silica, Sulphur, phosphorus and manganese. EN 1010 is a lowest amount of carbonalloy steel alloy with carbon content of 0.10%. Machineability of EN 1010 carbon steel is measured to be fairly good. EN 1010 is usually used for rivets and bolts, construction and automotive applications such as pans, nails and transmission cover. The objective of paper is to study the effect of process parameters namely pulse on time, pulse off time, peak current and servo voltage on surface roughness(SR).The effect of process parameters on productivity and accuracy facts is material dependent. To study parametric effect on Surface Roughness a Central Composite design approach of response surface methodology (RSM) is used to plan and study the experiments. The mathematical relationships between WEDM input process parameters and response parameter namely surface roughness is established to determine optimal values of surface roughness mathematically and graphically.The Analysis of variance (ANOVA) is performed to find statistically significant process parameters. Interaction effects of process parameters on surface roughness are analysed using statistical and graphical representations.
Neuro-symbolic is not enough, we need neuro-*semantic*Frank van Harmelen
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Neuro-symbolic (NeSy) AI is on the rise. However, simply machine learning on just any symbolic structure is not sufficient to really harvest the gains of NeSy. These will only be gained when the symbolic structures have an actual semantics. I give an operational definition of semantics as âpredictable inferenceâ.
All of this illustrated with link prediction over knowledge graphs, but the argument is general.
JMeter webinar - integration with InfluxDB and GrafanaRTTS
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Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overviewâ
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
To view the webinar recording, go to:
https://www.rttsweb.com/jmeter-integration-webinar
Securing your Kubernetes cluster_ a step-by-step guide to success !KatiaHIMEUR1
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Today, after several years of existence, an extremely active community and an ultra-dynamic ecosystem, Kubernetes has established itself as the de facto standard in container orchestration. Thanks to a wide range of managed services, it has never been so easy to set up a ready-to-use Kubernetes cluster.
However, this ease of use means that the subject of security in Kubernetes is often left for later, or even neglected. This exposes companies to significant risks.
In this talk, I'll show you step-by-step how to secure your Kubernetes cluster for greater peace of mind and reliability.
GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using Deplo...James Anderson
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Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
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The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. Whatâs changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
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The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties â USA
Expansion of bot farms â how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks â Europe
Systemic attacks in the Middle East
Download the full report from here:
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After immersing yourself in the blue book and its red counterpart, attending DDD-focused conferences, and applying tactical patterns, you're left with a crucial question: How do I ensure my design is effective? Tactical patterns within Domain-Driven Design (DDD) serve as guiding principles for creating clear and manageable domain models. However, achieving success with these patterns requires additional guidance. Interestingly, we've observed that a set of constraints initially designed for training purposes remarkably aligns with effective pattern implementation, offering a more âmechanicalâ approach. Let's explore together how Object Calisthenics can elevate the design of your tactical DDD patterns, offering concrete help for those venturing into DDD for the first time!
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
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Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
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My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 13, Issue 3 Ver. I (May- Jun. 2016), PP 46-50
www.iosrjournals.org
DOI: 10.9790/1684-1303014650 www.iosrjournals.org 46 | Page
Optimization of WEDM Process Parameters of EN47 Spring Steel
Based On Roughness Using Taguchi Method
S. Banerjee1
, S. Mitra2
, B. Panja3
1, 2
(Department Of Mechanical Engineering, Jalpaiguri Govt. Engg. College, West Bengal-735102, India)
3
(Department Of Mechanical Engineering, Narula Institute Of Technology, Kolkata-700109, India)
Abstract : The present paper deals with the experimental study of roughness (Ra) characteristics of EN 47
spring steel in WEDM and optimization of the machining process parameters based on L27 orthogonal design.
Experiments are carried out by utilizing the combination of four process parameters namely, pulse on time
(Ton), pulse off time (Toff), wire feed (WF) and gap voltage (V).The optimum combination of process parameters
for minimum roughness is obtained as Ton3Toff3WF1V1 i.e., highest levels of pulse on time and pulse off time
along with lower level of wire feed and gap voltage. Furthermore, a statistical analysis of variance (ANOVA) is
performed to find the significance of machining parameters and their interactions. It is observed that pulse on
time together with wire feed play a vital role in controlling the roughness characteristics of EN 47 spring steel.
A reduction of around 26% is observed in roughness at the optimal condition compared to the initial condition.
The composition of specimen material is studied with the help of chemical test.
Keywords :WEDM, EN47 spring steel, surface roughness, optimization, Taguchi method.
I. Introduction
Nowadays manufacturing sectors are emphasized on non-traditional machining processes due to
increasing demands of high surface finish and machining of complex shape geometries [1,2]. Wire Electrical
Discharge machining (WEDM) is an indispensable thermal machining process capable of accurately machining
parts of hard materials with intricate shapes. WEDM has grown as a simple means of making tools and dies to
the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy
[3,4]. The metal removal mechanism is due to melting and vaporization caused by the sufficiently high gap
voltage and electric spark, which increase the temperature about 10000ËC (that leads to melting and removing of
surface material). By this way the metal is removed from the work piece [5-7]. The WEDM processes are
having several performance characteristics like Metal Removal Rate, Surface roughness, Kerf width;
Dimensional error etc. Generally electrode material of WEDM is made of copper, brass, tungsten,
molybdenum etc. with diameter of range 0.05-0.30 mm [8,9]. A number of researchers focused on surface
roughness of WDEM and the pulse on time and wire feed rate are significantly affected on surface roughness
[10-13].
In this present work 27 experiments are conducted based on the L27 Orthogonal array considering
pulse on time, pulse off time, wire feed and gap voltages as control factors and the response measured is
surface roughness (Ra). Here EN 47 spring steel is used as the work piece. It is 1% chromium-vanadium type
spring steel, which is widely used in aerospace industries (smaller aircraftâs landing gear), motor vehicle
industries (material of leaf spring and coil spring), crank pin of heavy machineries, steering knuckles and disc
springs for heavily bolted sections [14]. The objective of the present study is to evaluate the roughness
characteristic of EN47 spring steel and optimization of WEDM process parameter for minimum surface
roughness based on Taguchi methodology.
II. Taguchi Method
In this present study, Taguchi method [15,16] is used to optimize the WEDM process parameters for
minimum roughness based on L27 orthogonal array that reduces the number of experiments. Thus, the cost and
time of experimentation is decreased. To measure the quality characteristics, Taguchi suggests the use of loss
function whichis statistically converted into Signal to noise ratio. Depending on the criteria of experiment, S/N
ratio is categorized as lower the better (LB), higher the better (HB) and Nominal the best (NB). For the present
study of roughness, lower the better criterion is used. Furthermore, a statistical analysis of variance (ANOVA) is
done to find the most significant parameters [17]. With the use of both S/N ratio and ANOVA analysis, the
optimal combination of process parameters can be predicted.
2. Optimization Of WEDM Process Parameters Of EN47 Spring Steel Based On Roughness Using
DOI: 10.9790/1684-1303014650 www.iosrjournals.org 47 | Page
III. Details of Experiment
3.1 Work piece material
EN47 spring steel is selected for this study. It is high carbon alloy steel with good harden ability. The
average microhardness value is 550 HV1. It is a tough oil quenching spring steel which when heat treated, offers
good wear resistance. The material composition is obtained by chemical test and It is shown in Table 1
Table 1 Chemical composition of EN 47 spring steel
Chemical
composition
(wt. %)
Carbon
(C)
Chromium
(Cr)
Manganese
(Mn)
Silicon
(Si)
Sulphur
(S)
Phosphorus (P) Vanadium
(V)
Desired 0.45-0.55 0.80-1.20 0.50-0.80 0.50
(Max.)
0.050
(Max.)
0.050 (Max.) 0.15
(Min.)
Obtained 0.42 0.91 0.81 0.23 0.030 0.027 0.17
3.2 Design of experiment
A scientific approach to plan the experiment is necessary for efficient conduct of experiments. While
design factors are applied to study the roughness behavior of the cutting material using WEDM. In present
study, design factors and their levels are shown in Table 2. It is a four-factor three-level experiment, so the total
degree of freedom (DOF) considering the individual factors and their interaction is 20. Here, L27 OA is selected
as it satisfies all the DOF conditions. The selected array requires the execution of 27 experiments. The factors
(Ton, Toff, WF and V) and their interactions (Ton ĂToff, Ton ĂWF and Toff ĂWF) are assigned to their respective
positions in the OA. Here roughness of EN47 spring steel is taken as the response variable.
Table 2 Design parameters and their levels
Design factors Unit Levels
1 2 3
Pulse on (Ton) ”s 4 6 8
Pulse off (Toff) ”s 8 10 12
Wire feed (WF) mm/min 6 8 10
Gap voltage (V) V 50 55 60
3.3 Machining operation
The experimental studies are performed on CNC controlled WEDM machine (JOEMARS WT355).
The pictorial view the WEDM is shown in Fig. 1 and the parameters which are kept constant during machining
are shown in Table 3.
Fig. 1 Pictorial view of WEDM
Table 3 Constant parameter of WEDM during machining
Parameter Value
Wire Copper wire, Ă 0.25mm
Shape cut 10Ă7 mm2
Thickness/ height of the work piece 13mm
Location of the work piece on work table At the center of table
Angle of cut Vertical
Drive system AC Servo Motor
Dielectric De-ionized water
3. Optimization Of WEDM Process Parameters Of EN47 Spring Steel Based On Roughness Using
DOI: 10.9790/1684-1303014650 www.iosrjournals.org 48 | Page
3.4 Roughness measurement
Surface roughness describes the morphological features on a real surface. Any real surface is not planar
but covered with microscopic hills, valleys, and even scratches. Surface roughness is a bulk measure of the
average size of the hills and valleys. A stylus type profilometer, Talysurf (MITUTOYO SJ210) is used to
measure the roughness (Ra) of the machining surface of EN47 spring steel. Roughness (Ra) measurement on the
machining surface is repeated five times and the average of the measurements is taken as the response for the
actual experiment.
IV. Results And Discussion
4.1 Signal to noise ratio analysis
Taguchi method utilizes the S/N ratio approach instead of the average value to convert the
experimental results into a value for the evaluation characteristic in the optimum parameter analysis. In the
present work, S/N ratio analysis is done with Ra as the performance index. Surface roughness is to be minimized
with the help of lower the better criterion. Table 4 shows the Ra values and corresponding S/N ratio values. The
average of S/N ratio of each level of the factors of Ton, Toff, WF and V is given in Table 5 and total average
value of S/N ratio of all the 27 experiments is also listed in this Table. It is found that process parameter Ton has
the highest delta value (rank 1). Hence, pulse on time has the maximum influence on roughness of EN47 spring
steel. Parameter WF and Toff also have some influence on the roughness. But parameter Toff has the least
influence on the roughness of EN47 spring steel. The optimal process parameter combination is the one that
yields maximum mean S/N ratio which is found to beTon3Toff3WF1V1.
Table 4: Experimental values of SR and their corresponding S/N ratio
Exp.
No.
Surface
roughness
(”m)
S/N Ratio Exp.
No.
Surface
roughness
(”m)
S/N Ratio Exp.
No.
Surface
roughness
(”m)
S/N Ratio
1 2.185 -6.789 10 2.164 -6.7052 19 2.736 -8.7423
2 2.878 -9.1818 11 2.582 -8.2391 20 2.501 -7.9623
3 2.262 -7.0899 12 2.029 -6.1456 21 2.45 -7.7833
4 2.584 -8.2459 13 2.51 -7.9935 22 2.092 -6.4112
5 2.52 -8.028 14 2.071 -6.3236 23 2.551 -8.1342
6 3.037 -9.6489 15 2.105 -6.465 24 1.86 -5.3903
7 2.262 -7.0899 16 2.421 -7.6799 25 1.938 -5.7471
8 2.187 -6.797 17 2.707 -8.6498 26 2.02 -6.107
9 2.198 -6.8406 18 2.779 -8.8778 27 2.55 -8.1308
Table 5 Response table for mean S/N ratio
Level Ton Toff WF V
1 -7.746 -7.627 -7.267 -7.321
2 -7.453 -7.405 -7.714 -7.528
3 -7.157 -7.324 -7.375 -7.506
Rank 1 3 2 4
Delta 0.589 0.302 0.447 0.207
Total mean S/N ratio = 7.452 dB
The main effect and interaction plots between the process parameters are shown in Fig. 2 and Fig. 3
respectively. In the main effects plot if the line for particular parameter has the highest inclination will have the
most significant effect. It is very much clear from the main effects plot that parameter Ton and WF are the most
significant parameters for controlling the roughness of EN47 spring steel. In case of interaction, parallel lines
indicate the absence of interaction between the factors, while non-parallel lines indicate the presence of
interaction between the factors. And if the lines intersect strong interaction is said to exist between those two
factors. Fig. 3 shows that there are strong interactions between Ton and Toff and Toff and WF.
Fig. 2 Main effect plot for signal-to-noise ratio
4. Optimization Of WEDM Process Parameters Of EN47 Spring Steel Based On Roughness Using
DOI: 10.9790/1684-1303014650 www.iosrjournals.org 49 | Page
(a) (b)
(c)
Fig. 3 Interaction plots for mean S/N ratio (a) Tonvs Toff, (b) Tonvs WF and (c) Toff vs WF
4.2 Analysis of variance (ANOVA)
To conduct an analysis of the relative importance of each factor more systematically, an analysis of
variance (ANOVA) is applied to the data. Analysis of variance finds out the significance of process parameters
and also the percentage contributions of the factors and the interactions in affecting the response. From table 6 it
is observed that parameter Ton i.e. pulse on time has got the maximum contribution in controlling the roughness
characteristics of EN47 spring steel. It is also seen that parameter WF i.e. wire feed has moderate contribution in
controlling the surface roughness of EN47 spring steel. Among the interactions, Ton*Toff gives the highest
contribution (39.39%) in controlling the surface roughness of EN47 spring steel while Toff*WF has reasonable
contribution to influence the roughness of EN47 spring steel within the experimental range in the study.
Table 6 Results of ANOVA for surface roughness
Source Degree of freedom Sum of square Mean square F-ratio % Contribution
Ton 2 1.562 0.781 0.42 4.844
Toff 2 0.441 0.22 0.12 1.37
WF 2 0.978 0.489 0.26 3.033
V 2 0.233 0.117 0.06 0.723
Ton*Toff 4 12.699 3.175 1.69 39.39
Ton*WF 4 0.463 0.116 0.06 1.44
Toff*WF 4 4.599 1.15 0.61 14.265
Error 6 11.265 1.878 34.941
Total 26 32.24 100
4.3 Confirmation test
Once the optimal level of the process parameters is achieved, it is necessary to carry out the
confirmation test to evaluate the accuracy of the analysis and validate the experimental results. Table 7 shows
the comparison of the estimated S/N ratio with the experimental S/N ratio using the optimal parameters. The
5. Optimization Of WEDM Process Parameters Of EN47 Spring Steel Based On Roughness Using
DOI: 10.9790/1684-1303014650 www.iosrjournals.org 50 | Page
mid-level combination of machining parameters i.e. Ton2Toff2WF2V2, is considered as the initial condition for
the present case. The increase of the S/N ratio from the initial condition to the optimal condition is found to be
about 1.8364dB. This implies that surface roughness is reduced around 26% from initial to optimal condition
and it is a significant improvement.
Table 7 Results of validation test
Initial condition Optimal condition
Prediction Experimentation
Level Ton2Toff2WF2V2 Ton3Toff3WF1V1 Ton3Toff3WF1V1
Ra (”m) 2.2905 1.854
S/N ratio (dB) -7.1986 -6.84401 -5.3622
Improvement of S/N ratio = 1.8364 dB
V. Conclusion
Taguchi orthogonal array is employed to optimize the WEDM process parameters with respect to
surface roughness of EN47 spring steel. It is seen that pulse on time and wire feed rate have the most signiïŹcant
inïŹuence in controlling roughness characteristics of the material. The interaction of pulse on time and pulse off
time and pulse on time and wire feed have adequate contribution to control the roughness behaviour. The
optimal parameter combination for minimum surface roughness is obtained as Ton3Toff3WF1V1 i.e., highest
levels of pulse on time and pulse off time along with lower level of wire feed and gap voltage. The surface
roughness is reduced by about 26 % from initial to optimal.
Acknowledgements
The authors gratefully acknowledge the research support provided by the Jalpaiguri Govt. Engineering
College, MSME Tool Room Kolkata and Narula Institute of Technology, India.
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