Electric discharge machining is used as machining of electrically conductive hard material. In EDM lots of techniques are applied to improve material removal rate.In this project ‘optimization of machining parameter’ technique is used to improve the MRR in EDM process.There are large number of machining parameters involves in machining the work piece by using EDM process. In this project work an experiment is performed to investigate and optimize the effect of four machining parameters i,e, discharge current, pulse on time, pulse off time,and voltage which is based on Taguchi Design Method.For performing this experiment copper tool (electrode) is used with the ‘mild steel’ workpiece,and kerosene as dielctric fluid has been choosen.Experiment is performed with L9 ORTHOGONAL ARRAY based on Taguchi design method. Signal-to-noise ratio is calculated to investigate the effect of input parameters more accurately.For analysis and explanation,graph is plotted between means of S/N ratio for mrr and four machining parameters ( current.Ton,TOFF, voltage) with the help of MINITAB 17 software.The model have been validated with analysis of variance (ANOVA).I found that discharge current has most significant factor,after that pulse on time,after that pulse off time and voltage has least significant effect
This document discusses using Grey relational analysis to optimize the parameters in rotary electrical discharge machining (EDM) of P20 steel. Experiments were conducted using an L18 orthogonal array to investigate the effects of workpiece polarity, discharge current, pulse on and off times, and tool rotational speed on material removal rate, tool wear rate, and surface roughness. Response tables and graphs were analyzed to determine the optimal parameter levels that maximize material removal rate while minimizing tool wear rate and surface roughness. Confirmation experiments validated the optimal results, demonstrating that Grey relational analysis is an effective technique for optimizing EDM process parameters.
IRJET- Multi Response Optimization of CNC Turning of Aluminum Alloy (AA-1199)...IRJET Journal
This document summarizes a research paper that investigated optimizing the cutting parameters of a CNC turning process for aluminum alloy AA-1199. The parameters considered were spindle speed, tool feed rate, and depth of cut. Experiments were conducted according to a Taguchi orthogonal array design. The responses measured were surface roughness and material removal rate. Analysis of variance and signal-to-noise ratios identified depth of cut as most significant for surface roughness and tool feed rate as most significant for material removal rate. The optimal parameters found were a spindle speed of 1300 rpm, tool feed of 0.25 mm/min, and depth of cut of 0.3 mm for minimum surface roughness.
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
The document describes an experiment to optimize cutting parameters for wire electrical discharge machining (WEDM) of titanium grade 5 alloy. Experiments were conducted using a Taguchi L25 orthogonal array to investigate the effects of pulse on time, pulse off time, peak current, wire tension, servo voltage, and servo feed rate on material removal rate and surface roughness. The experiments found that pulse on time, pulse off time, and peak current were the most significant factors influencing the performance measures. Analysis of the experimental results using signal-to-noise ratios identified the optimal machining parameters to maximize material removal rate while minimizing surface roughness.
Enhancing the Submersible Pump Rotor Performance by Taguchi Optimization Tech...IRJET Journal
The document describes an experimental study that used Taguchi optimization techniques to improve the surface roughness of rotor components made from silicon steel for submersible pumps. Three turning cutting parameters - cutting speed, feed rate, and depth of cut - were investigated at three levels each using an orthogonal array experiment. Analysis of variance was conducted on the surface roughness measurements to determine the most significant parameters. The results showed that cutting speed had the greatest influence on surface roughness, followed by depth of cut, while feed rate was less significant. This provides information on optimal cutting conditions for machining silicon steel rotors to reduce surface roughness.
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
IRJET- Determination of Surface Roughness in AA6063 using Response Surface Me...IRJET Journal
This document discusses using response surface methodology to optimize surface roughness in CNC turning of AA6063 aluminum alloy. Experiments were conducted to determine the effects of cutting speed, feed rate, and depth of cut on surface roughness. A Box-Behnken design and quadratic model were used to analyze the results. ANOVA showed that depth of cut had the greatest impact on surface roughness. A final equation was developed to predict optimal surface roughness values based on the input parameters. The results show that higher depth of cut leads to poorer surface roughness, while speed and feed rate have minimal effects.
Multi-Objective Optimization of EDM process parameters using Taguchi-Grey Rel...IRJET Journal
This document presents a study that uses Taguchi-Grey Relational Analysis to optimize the EDM process parameters for aluminum work material with a copper electrode. The objectives are to maximize the material removal rate and minimize the tool wear rate and surface roughness. Experiments are conducted with four machining parameters (discharge current, pulse on time, flushing pressure, and polarity) each at two levels. Response data is analyzed using Grey Relational Analysis to determine the optimal parameter combination and ranking. The optimal levels found are discharge current of 16A, pulse on time of 1010 μs, flushing pressure of 5kgf/cm2, and normal polarity. Analysis of variance indicates that discharge current has the most significant influence on the output responses
This document discusses using Grey relational analysis to optimize the parameters in rotary electrical discharge machining (EDM) of P20 steel. Experiments were conducted using an L18 orthogonal array to investigate the effects of workpiece polarity, discharge current, pulse on and off times, and tool rotational speed on material removal rate, tool wear rate, and surface roughness. Response tables and graphs were analyzed to determine the optimal parameter levels that maximize material removal rate while minimizing tool wear rate and surface roughness. Confirmation experiments validated the optimal results, demonstrating that Grey relational analysis is an effective technique for optimizing EDM process parameters.
IRJET- Multi Response Optimization of CNC Turning of Aluminum Alloy (AA-1199)...IRJET Journal
This document summarizes a research paper that investigated optimizing the cutting parameters of a CNC turning process for aluminum alloy AA-1199. The parameters considered were spindle speed, tool feed rate, and depth of cut. Experiments were conducted according to a Taguchi orthogonal array design. The responses measured were surface roughness and material removal rate. Analysis of variance and signal-to-noise ratios identified depth of cut as most significant for surface roughness and tool feed rate as most significant for material removal rate. The optimal parameters found were a spindle speed of 1300 rpm, tool feed of 0.25 mm/min, and depth of cut of 0.3 mm for minimum surface roughness.
This document summarizes an investigation into the effects of machining parameters on the surface finish and material removal rate when machining an aluminum-copper alloy (AL6351) using wire electric discharge machining (WEDM). The study uses Taguchi's design of experiments method to analyze the effects of pulse on-time, pulse off-time, and peak current. Sixteen experiments were conducted and the material removal rate and surface roughness were measured. The results were analyzed using ANOVA to determine the most significant parameters for improving surface finish and removal rate. The goal of the research was to optimize the WEDM process for machining AL6351 alloy.
The document describes an experiment to optimize cutting parameters for wire electrical discharge machining (WEDM) of titanium grade 5 alloy. Experiments were conducted using a Taguchi L25 orthogonal array to investigate the effects of pulse on time, pulse off time, peak current, wire tension, servo voltage, and servo feed rate on material removal rate and surface roughness. The experiments found that pulse on time, pulse off time, and peak current were the most significant factors influencing the performance measures. Analysis of the experimental results using signal-to-noise ratios identified the optimal machining parameters to maximize material removal rate while minimizing surface roughness.
Enhancing the Submersible Pump Rotor Performance by Taguchi Optimization Tech...IRJET Journal
The document describes an experimental study that used Taguchi optimization techniques to improve the surface roughness of rotor components made from silicon steel for submersible pumps. Three turning cutting parameters - cutting speed, feed rate, and depth of cut - were investigated at three levels each using an orthogonal array experiment. Analysis of variance was conducted on the surface roughness measurements to determine the most significant parameters. The results showed that cutting speed had the greatest influence on surface roughness, followed by depth of cut, while feed rate was less significant. This provides information on optimal cutting conditions for machining silicon steel rotors to reduce surface roughness.
Parametric Optimization of Graphite Plate by WEDMIRJET Journal
This document summarizes a study that used the Taguchi method to optimize the wire electrical discharge machining (WEDM) process parameters for machining graphite plates. Experiments were conducted using a WEDM machine to cut graphite plates with a 0.25mm brass wire. The process parameters investigated were current, pulse on time, pulse off time, and wire tension at three levels each based on an L9 orthogonal array design of experiments. Responses measured were material removal rate and surface roughness. Analysis of variance and signal-to-noise ratio graphs identified optimal parameters as 5A current, 5μs pulse on time, 25μs pulse off time, and 10gm wire tension for maximum material removal rate, and
IRJET- Determination of Surface Roughness in AA6063 using Response Surface Me...IRJET Journal
This document discusses using response surface methodology to optimize surface roughness in CNC turning of AA6063 aluminum alloy. Experiments were conducted to determine the effects of cutting speed, feed rate, and depth of cut on surface roughness. A Box-Behnken design and quadratic model were used to analyze the results. ANOVA showed that depth of cut had the greatest impact on surface roughness. A final equation was developed to predict optimal surface roughness values based on the input parameters. The results show that higher depth of cut leads to poorer surface roughness, while speed and feed rate have minimal effects.
Multi-Objective Optimization of EDM process parameters using Taguchi-Grey Rel...IRJET Journal
This document presents a study that uses Taguchi-Grey Relational Analysis to optimize the EDM process parameters for aluminum work material with a copper electrode. The objectives are to maximize the material removal rate and minimize the tool wear rate and surface roughness. Experiments are conducted with four machining parameters (discharge current, pulse on time, flushing pressure, and polarity) each at two levels. Response data is analyzed using Grey Relational Analysis to determine the optimal parameter combination and ranking. The optimal levels found are discharge current of 16A, pulse on time of 1010 μs, flushing pressure of 5kgf/cm2, and normal polarity. Analysis of variance indicates that discharge current has the most significant influence on the output responses
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
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 analyzes the effect of different wire electrodes on the material removal rate (MRR) of an MS workpiece using wire electrical discharge machining (WEDM). Experiments were conducted using copper, brass, and zinc-coated brass wire electrodes at various levels of current and pulse duration. The results showed that MRR was highest with copper wire and decreased with brass and zinc-coated brass wires. MRR also decreased with increasing current but increased with longer pulse duration. Statistical analysis through ANOVA confirmed that the wire material and pulse duration significantly affected the MRR while current had a lesser effect.
Optimization of machining parameters in edm of cfrp composite using taguchi t...IAEME Publication
1. The document summarizes a study that used Taguchi methods to optimize machining parameters for electrical discharge machining (EDM) of carbon fiber reinforced plastic (CFRP) composite material.
2. The study investigated the effects of gap voltage, discharge current, and pulse-on time on surface roughness. Experiments were conducted using an L9 orthogonal array.
3. Analysis of variance (ANOVA) and signal-to-noise ratios were used to analyze the results. It was found that discharge current had the most significant influence on surface roughness, and confirmation experiments validated the optimum parameters identified.
PROCESS PARAMETER OPTIMISATION IN WEDM OF HCHCR STEEL USING TAGUHI METHOD AND...IAEME Publication
Wire Electrical Discharge Machining (WEDM) is used as a valuable machining tool in the world of non-traditional machining due to various features which includes higher degree of accuracy, fine surface quality and good productivity. WEDM consists of large number of process parameters,
thus it is difficult to obtain a combination of optimum parameters which provides higher accuracy. Optimization of a single response is often carried out with the well known technique Taguchi method. This method results in the solution which gives optimum value of each response
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.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
This document presents an analysis of surface roughness characteristics during dry turning of medium carbon steel EN19. Experiments were conducted using a Taguchi L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on the surface roughness parameters Ra, Rq, and Rz. Grey relational analysis was used to determine the optimal process parameters that minimize all response variables. Regression models were developed to predict the surface roughness, which showed high correlation. Cutting speed was found to have the greatest influence on surface roughness based on ANOVA analysis.
Evaluation of Optimal Parameters for Surface Roughness Using Single Objective...IJERA Editor
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). Taguchi’s single objective optimization technique is used
to optimize the machining parameters in EDM for EN8 steel. For the experimentation Taguchi’s 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(131μs), Pulse-off time (POFF) level 2
(58μs), 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.
Designing, Fabricating, and Controlling of Shaped Metal Deposition System in ...Hassan Alwaely
This document summarizes Hassan Jasib Khudhair's master's thesis on designing, fabricating, and controlling a shaped metal deposition system for additive manufacturing. The research aims to develop a computer-aided double wire deposition machine controlled by a robotic arm. Experimental results show that process parameters like current, travel speed, and wire feed ratios influence bead geometry, hardness, and residual stress of deposited stainless steel parts. Finite element analysis of the system also shows that the design parameters allow for safe operation within specified stress limits. Overall, the study evaluates a new technique for additive manufacturing of metal parts using a cold wire feed method.
Experimental Study and Optimisation of Mrr In CNC Plasma ARC CuttingIJERA Editor
The research and development in the precise and accurate machining technology of hard metals (Ferrous, non-ferrous and glass etc) is gaining much importance in the industry since last many years. Due to the tremendous competition and cost factor, the non-conventional machining technology is becoming the first choice of the engineers and technicians. In this era of advanced technological processes the CNC plasma arc machining is gaining tremendous ground in the industry. It is much more capable of producing best finished, high accurate machining of very complicated non-symmetrical profile in no time. The main objective and targets of this practical experiment is based to achieve the best possible setting and parameters of operation on a CNC plasma arc machine to achieving speedy work i.e. Maximum material removal rate.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
This document describes research into optimizing the surface roughness of EN 1010 low alloy steel using wire electrical discharge machining (WEDM). Experiments were conducted using a central composite design to investigate the effects of four process parameters (pulse on time, pulse off time, peak current, and servo voltage) on surface roughness. Analysis of variance was used to identify significant parameters and develop a mathematical model relating the parameters to surface roughness. The model achieved a good fit to the data and can be used to determine the optimal parameter settings that minimize surface roughness.
IRJET- Optimization of Process Parameters on Inconel 718 using Taguchi’s Tech...IRJET Journal
This document summarizes a study that used Taguchi's technique to optimize cutting parameters during turning of Inconel 718 super alloy. Experiments were conducted on a CNC lathe to determine optimal settings for material removal rate (MRR) and surface roughness (Ra). An L9 orthogonal array was used to test cutting speed, feed rate, and depth of cut at three levels. Analysis of variance (ANOVA) found that depth of cut contributed most to MRR (52.925%) and feed rate contributed most to Ra (34.673%). The optimal parameters identified were cutting speed 80 m/min, feed 0.25 mm/rev, depth 0.2 mm for maximum MRR and cutting speed 80 m/
Application of non traditional optimization for quality improvement in tool ...iaemedu
This document discusses applying non-traditional optimization techniques to improve quality in tool holders. It begins with an abstract that describes using Taguchi's design of experiments, response surface methodology, and genetic algorithms to optimize grinding process parameters and minimize defects. The document then reviews literature on using techniques like genetic algorithms and particle swarm optimization to optimize machining processes. It presents the methodology used, which includes conducting experiments using an L9 orthogonal array to evaluate control parameters, developing a mathematical model relating parameters to quality, and using genetic algorithm and particle swarm optimization to minimize deviations from quality targets.
A comparative study of PSO, GSA and SCA in parameters optimization of surface...journalBEEI
The selection of parameters in grinding process remains as a crucial role to guarantee that the machined product quality is at the minimum production cost and maximum production rate. Therefore, it is required to utilize more advance and effective optimization methods to obtain the optimum parameters and resulting an improvement on the grinding performance. In this paper, three optimization algorithms which are particle swarm optimization (PSO), gravitational search, and Sine Cosine algorithms are employed to optimize the grinding process parameters that may either reduce the cost, increase the productivity or obtain the finest surface finish and resulting a higher grinding process performance. The efficiency of the three algorithms are evaluated and comparedwith previous results obtained by other optimization methods on similar studies.The experimental results showed that PSO algorithm achieves better optimization performance in the aspect of convergence rate and accuracy of best solution.Whereas in the comparison of results of previous researchers, the obtained result of PSO proves that it is efficient in solving the complicated mathematical model of surface grinding process with different conditions.
EFFECT OF PROCESS PARAMETERS ON SURFACE ROUGHNESS OF NICKEL BASED ALLOYS IN WEDMijmech
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 Taguchi’s method. Using Taguchi’s 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.
Parametric Optimization of Wire Electrical Discharge Machining (WEDM) Process...theijes
The document describes an experiment to optimize cutting parameters for wire electrical discharge machining (WEDM) of titanium grade 5 alloy. Experiments were conducted using a Taguchi L25 orthogonal array to investigate the effects of pulse on time, pulse off time, peak current, wire tension, servo voltage, and servo feed rate on material removal rate and surface roughness. The experiments found that pulse on time, pulse off time, and peak current were the most significant factors influencing the performance measures. Analysis of the experimental results using signal-to-noise ratios identified the optimal machining parameters to maximize material removal rate while minimizing surface roughness.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9µs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13µs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1µin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
This document describes a framework developed using Taguchi methods to optimize two quality characteristics, surface roughness and angular accuracy, in wire electrical discharge machining (W-EDM) operations. An experiment was conducted using an L9 orthogonal array to investigate the effects of four controllable factors (pulse on time, feed rate, voltage, and wire tension), each at three levels, on the two response variables. The optimal settings identified were able to improve both surface roughness and angular accuracy, as confirmed through additional validation experiments. This research established a systematic approach for obtaining a single optimal parameter setting to maximize multiple quality characteristics simultaneously in machining applications.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
Process Parameter Optimization of WEDM for AISI M2 & AISI H13 by Anova & Anal...IJERA Editor
The document summarizes a study on optimizing process parameters for wire electrical discharge machining (WEDM) of AISI M2 and AISI H13 steel alloys. Experiments were conducted using a Taguchi L16 orthogonal array with peak current, pulse on time, pulse off time, and workpiece material as parameters. Responses measured included material removal rate, surface roughness, kerf width, and spark gap. ANOVA showed peak current and pulse on time most significantly affected responses. For AISI M2, low peak current, short pulse on and off times minimized surface roughness and kerf width while maximizing material removal rate. For AISI H13, low peak current, long pulse on time
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
Optimization of WEDM Process Parameters on Titanium Alloy Using Taguchi MethodIJMER
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 analyzes the effect of different wire electrodes on the material removal rate (MRR) of an MS workpiece using wire electrical discharge machining (WEDM). Experiments were conducted using copper, brass, and zinc-coated brass wire electrodes at various levels of current and pulse duration. The results showed that MRR was highest with copper wire and decreased with brass and zinc-coated brass wires. MRR also decreased with increasing current but increased with longer pulse duration. Statistical analysis through ANOVA confirmed that the wire material and pulse duration significantly affected the MRR while current had a lesser effect.
Optimization of machining parameters in edm of cfrp composite using taguchi t...IAEME Publication
1. The document summarizes a study that used Taguchi methods to optimize machining parameters for electrical discharge machining (EDM) of carbon fiber reinforced plastic (CFRP) composite material.
2. The study investigated the effects of gap voltage, discharge current, and pulse-on time on surface roughness. Experiments were conducted using an L9 orthogonal array.
3. Analysis of variance (ANOVA) and signal-to-noise ratios were used to analyze the results. It was found that discharge current had the most significant influence on surface roughness, and confirmation experiments validated the optimum parameters identified.
PROCESS PARAMETER OPTIMISATION IN WEDM OF HCHCR STEEL USING TAGUHI METHOD AND...IAEME Publication
Wire Electrical Discharge Machining (WEDM) is used as a valuable machining tool in the world of non-traditional machining due to various features which includes higher degree of accuracy, fine surface quality and good productivity. WEDM consists of large number of process parameters,
thus it is difficult to obtain a combination of optimum parameters which provides higher accuracy. Optimization of a single response is often carried out with the well known technique Taguchi method. This method results in the solution which gives optimum value of each response
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.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
This document presents an analysis of surface roughness characteristics during dry turning of medium carbon steel EN19. Experiments were conducted using a Taguchi L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on the surface roughness parameters Ra, Rq, and Rz. Grey relational analysis was used to determine the optimal process parameters that minimize all response variables. Regression models were developed to predict the surface roughness, which showed high correlation. Cutting speed was found to have the greatest influence on surface roughness based on ANOVA analysis.
Evaluation of Optimal Parameters for Surface Roughness Using Single Objective...IJERA Editor
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). Taguchi’s single objective optimization technique is used
to optimize the machining parameters in EDM for EN8 steel. For the experimentation Taguchi’s 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(131μs), Pulse-off time (POFF) level 2
(58μs), 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.
Designing, Fabricating, and Controlling of Shaped Metal Deposition System in ...Hassan Alwaely
This document summarizes Hassan Jasib Khudhair's master's thesis on designing, fabricating, and controlling a shaped metal deposition system for additive manufacturing. The research aims to develop a computer-aided double wire deposition machine controlled by a robotic arm. Experimental results show that process parameters like current, travel speed, and wire feed ratios influence bead geometry, hardness, and residual stress of deposited stainless steel parts. Finite element analysis of the system also shows that the design parameters allow for safe operation within specified stress limits. Overall, the study evaluates a new technique for additive manufacturing of metal parts using a cold wire feed method.
Experimental Study and Optimisation of Mrr In CNC Plasma ARC CuttingIJERA Editor
The research and development in the precise and accurate machining technology of hard metals (Ferrous, non-ferrous and glass etc) is gaining much importance in the industry since last many years. Due to the tremendous competition and cost factor, the non-conventional machining technology is becoming the first choice of the engineers and technicians. In this era of advanced technological processes the CNC plasma arc machining is gaining tremendous ground in the industry. It is much more capable of producing best finished, high accurate machining of very complicated non-symmetrical profile in no time. The main objective and targets of this practical experiment is based to achieve the best possible setting and parameters of operation on a CNC plasma arc machine to achieving speedy work i.e. Maximum material removal rate.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
This document describes research into optimizing the surface roughness of EN 1010 low alloy steel using wire electrical discharge machining (WEDM). Experiments were conducted using a central composite design to investigate the effects of four process parameters (pulse on time, pulse off time, peak current, and servo voltage) on surface roughness. Analysis of variance was used to identify significant parameters and develop a mathematical model relating the parameters to surface roughness. The model achieved a good fit to the data and can be used to determine the optimal parameter settings that minimize surface roughness.
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Abstract
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Modeling of Morphology and Deflection Analysis of Copper AlloysIRJET Journal
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IRJET- Parametric Optimisation of Submerged ARC Welding Process by using Resp...IRJET Journal
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Parameter Optimization of Wire EDM in a Range of Thickness for EN8 Die SteelIJTET Journal
Wire Electrical Discharge Machining (WEDM) is also known as an electro thermal production process in then, nor
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to parameter optimization in wire electric discharge machining of EN-8 die steel (of thickness 50 and 75mm) using Taguchi
method which optimizes four process parameters (factors) such as pulse ON time, pulse OFF time, current, voltage and two
important response such as material removal rate (MRR) and in surface roughness (Ra –average roughness) of machined
workpiece is considered in this study. Taguchi is an efficient search technique, is used to obtain the optimal setting of the desired
responses and to avoid the conflicting nature of response. Taguchi designs focus on reducing variability, as well as setting the mean to target.
This document summarizes a study on optimizing electric discharge machining (EDM) parameters to maximize material removal rate (MRR) and minimize electrode wear rate (EWR) when machining stainless steel 316 with a copper electrode. Experiments were conducted using a Taguchi design of experiments with four machining parameters (pulse on time, pulse off time, current, fluid pressure) each at three levels. Results showed that pulse off time and current had the most significant effects on MRR and EWR, respectively. Specifically, MRR increased with longer pulse off times while EWR decreased at higher currents. The optimal settings found were a current of 12 amps and long pulse off time to achieve maximum MRR during EDM of
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
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IRJET- Tensile and Shear Strength Approximate Prediction of Friction Surf...IRJET Journal
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Improving Material Removal Rate and Optimizing Variousmachining Parameters in EDM
1. The International Journal of Engineering and Science (IJES)
|| Volume || 6 || Issue || 6 || Pages || PP 64-68 || 2017 ||
ISSN (e): 2319 – 1813 ISSN (p): 2319 – 1805
DOI: 10.9790/1813-0606016468 www.theijes.com Page 64
Improving Material Removal Rate and Optimizing
Variousmachining Parameters in EDM
*Vivek Kumar ** Prakash Kumar
*Research Scholar, Mechanical Engineering Department
**Assistant Professor, Production Engg. Department B.I.T. Sindri, Dhanbad
--------------------------------------------------------ABSTRACT-----------------------------------------------------------
Electric discharge machining is used as machining of electrically conductive hard material. In EDM lots of
techniques are applied to improve material removal rate.In this project ‘optimization of machining parameter’
technique is used to improve the MRR in EDM process.There are large number of machining parameters
involves in machining the work piece by using EDM process. In this project work an experiment is performed to
investigate and optimize the effect of four machining parameters i,e, discharge current, pulse on time, pulse off
time,and voltage which is based on Taguchi Design Method.For performing this experiment copper tool
(electrode) is used with the ‘mild steel’ workpiece,and kerosene as dielctric fluid has been choosen.Experiment
is performed with L9 ORTHOGONAL ARRAY based on Taguchi design method. Signal-to-noise ratio is
calculated to investigate the effect of input parameters more accurately.For analysis and explanation,graph is
plotted between means of S/N ratio for mrr and four machining parameters ( current.Ton,TOFF, voltage) with the
help of MINITAB 17 software.The model have been validated with analysis of variance (ANOVA).I found that
discharge current has most significant factor,after that pulse on time,after that pulse off time and voltage has
least significant effect.
-------------------------------------------------------------------------------------------------------------------------
Date of Submission: 02 June 2017 Date of Accepted: 24 June 2017
--------------------------------------------------------------------------------------------------------------------------------------
I. INTRODUCTION
Electric discharge machining is a non traditional manufacturing process based on removing material from a part
by means of a series of repeated electrical discharge( created by electric pulse generators at short interval)
between a tool,calledelectrode,and the part being machined in the presence of a dielectric fluid.In other words
we can say in this procedure metal is removed from the work-piece due to erosion caused by rapidly formed
spark discharge taking place between tool and work piece.This process is used to produce dies,punches and
moulds,finishing parts for aerospace and automotive industry,and surgical components.
Figure of electric discharge machining process
2. Improving Material Removal Rate And Optimizing Variousmachining Parameters In Edm
DOI: 10.9790/1813-0606016468 www.theijes.com Page 65
II. LITERATURE REVIEW
There is discussed below some research paper related to EDM.The studies carried out in these papers are
mainly concerned with EDM parameter such as current,voltage,pulse on time,duty cycle etc and how these
affect the material removal rate.
(a) B.S.Reddy carried out a study on the effect of EDM parameters over metal removal rate,tool wear rate,
surface roughness and hardness.Mixed factorial design of experiments and multiple regression analysis
techniques had been employed to achieve the desired results.The parameters in the decreasing order of
importance for Mrr -duty cycle,current and voltage,Twr-current,servo duty cycle.
(b) M MRahman investigate the effect of peak current and pulse duration on performance characteristics of
EDM.The conclusion drawn were,the current and pulse on time greatly affected the Mrr,Twr and
SR.TheMrr increases almost linearly with increasing current for different pulse on time.
(c) Iqbal and khan concluded that the voltage and rotational speed of the electrode are the two significant
parameters for EDM milling.Optimizing the EWR.
(d) T.Rajmohan experimented using design of experiment technique under L9 Orthogonal array design and
considering the effect of machining parametrs of EDM such as pulse on time,pulse off time, current and
voltage on mrr in machining of AISI304 stainless steel.For optimization they had been used signal to noise
ratio and analysis of variance to analyze the effect of the parameters on mrr and also optimize the cutting
parameters.
III. PROBLEMSTATEMENT
In EDM,the selection of parameters play a main role in producing good surface quality,highMrr and less
electrode wear.This research aim is to investigate the proper selection of parameters in EDM for machining
hundred material and studies these selected different parameters which are able to deliver better results in terms
of material remoival rate and electrode wear of mild steel by copper electrode.Some machining parameters are
such as pulse on time,pulse off time,arcgap,dischargecurrent,dutycycle,voltage etc.The problem might be
interfere the result in this experiment when selection of parameters are not suitable and unproper to investigate
on these machining characteristics
IV. OBJECTIVE OF PRESENT WORK
The objective of this project work is to improve Mrr of mild steel work piece with copper tool by optimizing
four machining parameters pulse on time,pulse off time,current and discharge voltage.
V. SELECTION OF WORK PIECE
In this experiment mild steel size 80×60×15mm×mm×mm plate is chosen for conductive experiment.Mild steel
has use in manufacturing industries.It offered in an extensive veriety of good products,practices and qualities
than any other.It has excellent welding and forming characteristics, and it has very good corrosion resistance.
VI. SELECTION OF TOOL MATERIAL
In this experiment copper tool rod of 8 mm dia and 60mm length of cylindricalshape are taken.
FORMULA OF MATERIAL REMOVAL CALCULATION
MRR is calculated as proportion of change of weight of work piece before and after machining to the product of
machining period and density of material.
M.R.R.= (Wbm- Wam) ÷ ( t ×ῥ)
Where,
Wbm = weight of work piece before machining
Wam= weight of work piece after machining
t = machining period = 1 minute
ῥ = Density of mild steel work piece=8000kg/m3
3. Improving Material Removal Rate And Optimizing Variousmachining Parameters In Edm
DOI: 10.9790/1813-0606016468 www.theijes.com Page 66
VII. TAGUCHI DESIGNMETHOD
Dr. Genichi Taguchi of Nippon telephones & telegraph company,japan has developed a method based on
“ORTHOGONAL ARRAY” experiments which gives much reduced “variance” for the experiment with
optimum settings of control parameters.
Hence,design of experiments with optimization of control parameters to obtain best result is achieved in
Taguchi method.
Although various factors could be considered for controlling EDM process,but in the present project work,four
process parameters namely discharge current, pulse-on-time,pulse-off time and average voltage are considered.
In this project work taguchi method is used to find out the optimal machining parameters for maximization of
mrr in EDM process.
This method use the loss function to measure the performance parameters deviating from the desired value. The
value of loss function is further transformed into a signal-to-noise (S/N) ratio.
There are mainly 3 types of performance parameters in the analysis of the S/N ratio which is as follows:-
(a)Smaller-the-better
(b) Nominal-the-better
(c) Larger-the-better
The value of S/N ratio for each level of process parameters is computed based on S/N analysis. The
characteristics of higher value represents better machining performance.For example material removal rate is
termed as Larger-the-better.
Characteeristic of lower value represents better machining performance. For example surface roughness is
termed as lower-is –better.
Hence it is concluded that for material removal rate “larger-is –better” were selected for finding optimum
machining parameters.
VIII. MACHINING PARAMETERS AND THEIR LEVEL
SYMBOL MACHINING
PARAMETERS
UNIT LEVELS
LEVEL1 LEVEL2 LEVEL3
A PEAK CURRENT AMPERE 4 6 8
B PULSE ON TIME SECOND 40 80 120
C PULSE OFF TIME SECOND 30 40 50
D VOLTAGE VOLT 40 50 60
IX. TAGUCHI ORTHOGONAL ARRAY EXPERIMENT
MINITAB 17 Software is used for design of experiment in taguchi analysis.This software offers many possible
ways in which an experiment can be carried out. A number of ordinary orthogonal arrays have been created to
ease of experimental design.A number of ordinary orthogonal arrays have been created to ease of experimental
design.A number of orthogonal arrays,such as L4, L8, L9, L12, L18, L27 and so on created for two or three level
factors.In this project, an L9 orthogonal array with four column and nine rows has has been used.This array had
10 degree of freedom and it uses 3-level design machining parameters.Here nine experiments are required to
study the entire parameter space using L9 orthogonal array.In first column, peak current,second turn-on-time,3rd
turn off time and 4th
column voltage has indicated.
X. ANALYSIS OF SIGNAL TO NOISE (S/N) RATI0
Since,There Are 3 Types Of Performance Characteristics I,E Smaller-The-Better,The –Larger-The –
Better.To Find Out Optimal Machining Performance,Greater-The-Bettercharacteristics for material
removal rate has been taken for obtaining optimal machining performance.
The loss function (L) for objective of greater better is defined as follows:-
LG.B =1/n ∑i=1 to n 1/Yimrr
2
Yi→is experimentally observed value
Where Yimrr denotes response for material removal rate
n denotes number of experiments.
The S/N ratio response parameter can be calculated as a logarithmic of the loss function as shown below in
Taguchi L9 orthogonal array design.
S/N for MRR,
ή = -10 log10 1/n ∑i=1 to n 1/Yimrr
2
4. Improving Material Removal Rate And Optimizing Variousmachining Parameters In Edm
DOI: 10.9790/1813-0606016468 www.theijes.com Page 67
XI. EXPERIMENTAL DESIGN USING L9 ORTHOGONAL ARRAY FOR COPPER
ELECTRODES
EXP.NO. IP Ton Toff V wt.B.M. wt.A.M. MRR S/N ratio
1 4 40 30 40 120.230 120.045 1.963 5.858
2 4 80 40 50 120.045 119.755 3.078 9.765
3 4 120 50 60 119.755 119.513 2.569 8.195
4 6 40 50 50 119.513 119.141 3.949 11.929
5 6 80 30 60 119.141 118.680 4.893 13.791
6 6 120 40 40 118.680 118.262 4.437 12.941
7 8 40 40 60 118.262 117.671 6.273 15.949
8 8 80 50 40 117.671 116.951 7.643 17.665
9 8 120 30 50 116.951 116.282 7.101 17.026
EFFECT OF INPUT FACTORS ON MRR
With the help of MINITAB 17 software the plot between means of S/N ratio for mrr and discharge current has
been plotted.Also plot between means of S/N ratio for mrr and pulse-on-time, plot between means of S/N rario
for mrr and pulse-off-time,and plot between means of S/N ratio for mrr and voltage has been plotted as shown in
figure below:
If line for a particular parameter is near horizontal,then the parameters has no significant effect.And if a
parameter for which the line has the highest inclination will have the most significant effect.It is obvious from
the four plots below, the parameter discharge current(I) has the most significant effect.From figure 2 ,Turn-on-
time has moderate significant effect and TOFF has least significant effect. Hence we can concluded that
discharge current (I) is the most influencing parameter for the EDM process.According to taguchi design of
experiment Greater-the-better quality characteristics for MRR of copper electrode,the optimum condition for
each factor indicated is current8 amp,pulse on time80 second,pulse off time50 second,voltage40 volt.The
optimal process parameter combination for maximum metal removing rate is found to be discharge current at
highest level,pulse on time at second highest level,voltageat3rd
highest level & pulse off time at lowest
level.Mean S/N ratio for each level of parameters are called mean S/N response table for MRR. Here cutting
tool is made up of copper element,so the effect of machining parameter can be ranked as follows.
5. Improving Material Removal Rate And Optimizing Variousmachining Parameters In Edm
DOI: 10.9790/1813-0606016468 www.theijes.com Page 68
TABLE-2- s/n RATIO RESPONSE TABLE FOR MRR
LEVEL IP Ton Toff V
1 7.939 11.245 12.225 12.154
2 12.887 13.740 12.885 12.906
3 16.88 12.720 12.596 12.645
DELTA 8.941 3.515 0.949 1.013
RANK 1 2 4 3
With the help of responsetable ANOVA IS performed to find out which machining parameters significantly
affect the output characteristics. Table 3- shows ANOVA results for MRR for copper electrode.This table shows
% contribution of each parameter. For, MRR S/N ratio follows „Greater-is –better‟ criteria. From the table
below discharge current hasmaximum effect and Toff time has minimum effect and Ton has moderate effect on
mrr of EDM Process parameters.
XII. .ANOVA RESULT FOR MRR USING CU ELECTRODE (TABLE 3)
Sequence of variation DOF Squential sum
of squares
Mean
square(variance)M.S.=SF/DF
Contribution
IP 2 120.368 60.184 91.64%
Ton 2 9.441 4.7025 7.18%
Toff 2 0.656 0.328 o.49%
Voltage 2 o.874 o.437 o.66%
Residual error 2
Total 10 131.339
XIII. RESULT AND DISCUSSION
From the Anova result for MRR using cu electrode as shown in table-3 below.It is clear that discharge current with a
contribution of 91.64% has the greatest effect on performance characteristics (output characteristics).
Next parameter turn on time with a contribution of 7.18% has the next greatest effect on performance characteristics, after
that voltage whose contribution is 0.66% and the last parameter Toff time has contribution 0.49% has least effect on
performance characteristics.
XIV. CONCLUSION
In this investigation experiment on electric discharge machining to know the effect of machining outputs taken for
consideration is material removal rate of the mild steel work piece using copper electrode tool by taguchi design method and
improvement of mrr has been investigated.The experiment depends on various parameters for example discharge current,
pulse-on-time (Ton), pulse-off-time and voltage has been selected.This experiment is based on L9 orthogonal array by
taguchi design is conducted and minitab 17 software is used for this experiment.The main conclusion of this research are as
follows:-
(a) Material removal rate of electric discharge machining can be improved by using optimization of various factors
(discharge current,Ton,Toff,voltage) as determined within this work.
(b) Discharge current has most significant parameters for mrr.
(c) Voltage,& Ton time is moderately effect the material removal rate.
(d) Toff has the least significant influence on MRR.
(e) The optimal process parameters that have been seen aboveobservationtable,the best contribution of process variables
are current 8 ampere,Ton 80 second,voltage 40 volt.,Toff 50 second , for copper electrode
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