This document describes using a relevance vector machine (RVM) to predict material removal rate (MRR) and surface roughness (SR) in an electrochemical machining (ECM) process. Experiments were conducted using an L18 orthogonal array to test combinations of voltage, feed rate, and electrolyte flow rate. An RVM model was developed using these inputs to predict MRR and SR outputs. The model performance was evaluated by comparing predicted and experimental outputs to calculate regression error. Results showed the RVM with a Laplace kernel function minimized regression error in predicting MRR and SR for the ECM process.
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
electricity) allows the wire to cut through the metal by the use of heat from electrical sparks. The present work process approach
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.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
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
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
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.
The document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR...meijjournal
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.
ANALYSIS OF THE EFFECT OF ULTRASONIC VIBRATIONS ON THE PERFORMANCE OF MICROEL...ijmech
The document analyzes the effect of ultrasonic vibrations on the performance of micro-electrical discharge machining (micro-EDM) of A2 tool steel. It first discusses challenges with micro-EDM at low discharge energies and how ultrasonic vibration-assisted micro-EDM helps address these challenges by improving flushing of debris from the gap. The document then analyzes experimental data on material removal rate (MRR) and tool wear rate (TWR) under different processing conditions. Analysis of means plots and interaction plots show that MRR increases with capacitance, vibration power, and feed rate, but decreases with machining time, while TWR generally decreases with capacitance but increases with vibration power. Regression equations
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
electricity) allows the wire to cut through the metal by the use of heat from electrical sparks. The present work process approach
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.
Multi-Response Optimization of WEDM Process Parameters of Monel 400 using Int...ijceronline
Non-traditional machining processes such as Wire Electric Discharge Machining (WEDM) are increasingly been employed to machine difficult-to-machine materials. Monel 400 an alloy of Nickel and Copper is taken in this study and it is cut through Wire Electric Discharge Machining process. It is utilized mainly in corrosion resistant applications. Further, the process parameters are optimized to get the desired machining conditions which can improve the quality of machining. Design of Experiments is done through Central Composite Design (CCD). Response Surface Methodology (RSM) and Genetic Algorithm (GA) which is an evolutionary algorithm are the techniques employed for the optimization of parameters in WEDM. The multi response optimization for achieving maximum material removal rate (MRR) and minimum surface roughness, the optimum process parameters are found to be ‘Current’ of 2.031 A, ‘T-On’ of 3 µs, ‘T-Off’ of 10 µs, the obtained maximum MRR is 6.339 mm 3 /min and minimum surface roughness is 1.846 µm.
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
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
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.
The document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
ANALYSIS AND STUDYTHE EFFECTSOFVARIOUS CONTROL FACTORS OF CNC-WIRE CUT EDMFOR...meijjournal
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.
ANALYSIS OF THE EFFECT OF ULTRASONIC VIBRATIONS ON THE PERFORMANCE OF MICROEL...ijmech
The document analyzes the effect of ultrasonic vibrations on the performance of micro-electrical discharge machining (micro-EDM) of A2 tool steel. It first discusses challenges with micro-EDM at low discharge energies and how ultrasonic vibration-assisted micro-EDM helps address these challenges by improving flushing of debris from the gap. The document then analyzes experimental data on material removal rate (MRR) and tool wear rate (TWR) under different processing conditions. Analysis of means plots and interaction plots show that MRR increases with capacitance, vibration power, and feed rate, but decreases with machining time, while TWR generally decreases with capacitance but increases with vibration power. Regression equations
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
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
This document summarizes a study on using simulated annealing algorithm to predict weld bead geometry in gas metal arc welding. Key points:
1. The study develops mathematical models using multiple regression to predict four dimensions of weld bead geometry based on welding process parameters.
2. Experiments are conducted using a central composite design with five levels and factors including current, welding speed, gun angle, contact tip distance, and pinch.
3. The developed models are checked for adequacy and significance. Bead geometry is then predicted again using a simulated annealing algorithm for comparison.
Prediction of Weld Pool Geometry in Pulsed Current Micro Plasma Arc Welding o...drboon
Pulsed Micro Plasma Arc Welding (MPAW) is a metal joining technique widely used in manufacturing of thin sheet components due to its inherent properties. The weld quality and productivity are controlled by the process parameters. The paper discuses about development of mathematical models for weld pool geometry of stainless steel 304L sheets. Design of experiments based on full factorial design is employed for the development of a mathematical model correlating the important controlled pulsed MPAW process parameters like peak current, background current, pulse and pulse width with front width, back width, front height and back height. The developed mode has been checked for adequacy based on ANOVA analysis. Weld bead parameters obtained by the models are found to confirm actual values with high accuracy. Using these models effect of pulsed MPAW process parameters on weld pool geometry are studied.
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 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.
Comparison of fuzzy logic and neural network for modelling surface roughness ...ijmech
Surface roughness is the main indicator of technological performances of a component for electrical discharge machining (EDM). EDM process of manganese alloyed cold-work tool steel was modelled. In this paper we used the fuzzy logic (FL) and neural network (NN) to predict the effect of machining variables (discharge current and pulse duration) on the surface roughness of manganese alloyed cold-work tool steel in order to improve and increase its range of application. The experiments are carried out on
manganese alloyed cold-work tool steel, processed with electrodes made of copper. The values of surface
roughness predicted by these models are then compared. All models show good agreement with experimental results. When compared to the NN and FL models, the NN model has shown a significant forecast improvement. The results indicate that the NN model is an effective algorithm to forecast the surface roughness in EDM.
Parametric Optimization of Electrochemical Machining Using Signal-To-Noise (S...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
The document describes a study that developed an artificial neural network (ANN) model to predict surface roughness, cutting force, and temperature during machining of Nimonic-75 and Nicrofer C-263 super alloys. Experiments were conducted to collect input/output data on cutting speed, feed rate, depth of cut, surface roughness, cutting force, and temperature. The ANN model was trained on this data and could accurately model the complex relationships between cutting conditions and output parameters for process analysis and optimization.
Aspects Regarding the Elastic Properties of Silicon and Its Influence on the ...IRJET Journal
This document summarizes research on modeling the elastic properties of silicon and how it influences the behavior of micro-mechanical components like MEMS sensors. Finite element modeling was used to simulate the vibration modes and resonant frequencies of silicon micro-cantilever beams. Silicon was modeled as both an isotropic and orthotropic material using different elastic modulus values from literature. The simulation results were compared to analytical calculations and experimental measurements using laser Doppler vibrometry and atomic force microscopy. Modeling silicon as an orthotropic material with different elastic properties along crystal axes provided the best match to experimental frequency values, with errors less than 3% for bending modes.
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
This document summarizes a study that used the Taguchi method to analyze the effect of parameters like voltage, current, and pulse on time on material removal rate (MRR) and surface roughness (SR) during CNC EDM of SK-5 material. Experiments were conducted based on an L9 orthogonal array with 3 factors at 3 levels. Analysis found voltage had the largest effect on MRR while pulse on time most influenced SR. The optimized parameters were experiment 4 for MRR and experiment 7 for SR. In conclusion, the Taguchi method helped determine the best settings of CNC EDM parameters for machining SK-5.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
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.
This document summarizes a research study on optimizing parameters for the electrochemical machining process to maximize the material removal rate when machining Hastelloy C-276. The researchers conducted experiments using a Taguchi design of experiments with three machining parameters (feed rate, electrolyte flow rate, and voltage) each set at three levels. The highest material removal rate was achieved at a high feed rate of 1 mm/min, low electrolyte flow rate of 150 L/hr, and high voltage of 16V. Analysis of the results showed that feed rate had the strongest influence on material removal rate, with higher feed rates increasing the rate.
International Journal of Engineering Research and DevelopmentIJERD Editor
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.
EFFECT OF EDM PARAMETERS IN OBTAINING MAXIMUM MRR AND MINIMUM EWR BY MACHININ...IAEME Publication
EDM machining is used for very hard and complex cutting of conducting materials with higher surface finish and close dimensions. EDM process parameters are affected by both electrical and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on electro discharge machine with copper as cutting tool electrode. This paper presents the effect of control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge Machine.
The document describes an experimental study on the effect of vibration on micro-electro-discharge machining (μEDM). Response surface methodology was used to develop mathematical models for material removal rate and tool wear rate based on experiments using a central composite design. Analysis of variance was performed to verify the models. The results show that applying vibration to the workpiece during μEDM can impact process performance characteristics like material removal rate and tool wear rate. The developed models can be used to determine optimal input parameter values for the μEDM drilling process.
The entire research work is experiment oriented and the conclusions are drawn based on
graphical analysis of experimental results. The research work carried out reveals that the findings are
encouraging in establishing the effect of Voltage, Capacitance and work piece vibration Frequency,
amplitude on different materials µEDM drilling process performance characteristics. The results of
this investigations can be adopted in deciding the optimal values of input process parameters µEDM
drilling process
The document describes an experimental study that uses response surface methodology to develop mathematical models for material removal rate (MRR) and tool wear rate (TWR) in micro-electro-discharge machining (μEDM) as functions of voltage, capacitance, and workpiece vibration frequency and amplitude. Central composite design was used to generate experimental data, and analysis of variance was performed to verify the adequacy of the developed models within a given confidence interval. The results provide information on optimizing input process parameters for μEDM drilling.
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
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
This document summarizes a study on using simulated annealing algorithm to predict weld bead geometry in gas metal arc welding. Key points:
1. The study develops mathematical models using multiple regression to predict four dimensions of weld bead geometry based on welding process parameters.
2. Experiments are conducted using a central composite design with five levels and factors including current, welding speed, gun angle, contact tip distance, and pinch.
3. The developed models are checked for adequacy and significance. Bead geometry is then predicted again using a simulated annealing algorithm for comparison.
Prediction of Weld Pool Geometry in Pulsed Current Micro Plasma Arc Welding o...drboon
Pulsed Micro Plasma Arc Welding (MPAW) is a metal joining technique widely used in manufacturing of thin sheet components due to its inherent properties. The weld quality and productivity are controlled by the process parameters. The paper discuses about development of mathematical models for weld pool geometry of stainless steel 304L sheets. Design of experiments based on full factorial design is employed for the development of a mathematical model correlating the important controlled pulsed MPAW process parameters like peak current, background current, pulse and pulse width with front width, back width, front height and back height. The developed mode has been checked for adequacy based on ANOVA analysis. Weld bead parameters obtained by the models are found to confirm actual values with high accuracy. Using these models effect of pulsed MPAW process parameters on weld pool geometry are studied.
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 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.
Comparison of fuzzy logic and neural network for modelling surface roughness ...ijmech
Surface roughness is the main indicator of technological performances of a component for electrical discharge machining (EDM). EDM process of manganese alloyed cold-work tool steel was modelled. In this paper we used the fuzzy logic (FL) and neural network (NN) to predict the effect of machining variables (discharge current and pulse duration) on the surface roughness of manganese alloyed cold-work tool steel in order to improve and increase its range of application. The experiments are carried out on
manganese alloyed cold-work tool steel, processed with electrodes made of copper. The values of surface
roughness predicted by these models are then compared. All models show good agreement with experimental results. When compared to the NN and FL models, the NN model has shown a significant forecast improvement. The results indicate that the NN model is an effective algorithm to forecast the surface roughness in EDM.
Parametric Optimization of Electrochemical Machining Using Signal-To-Noise (S...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
The document describes a study that developed an artificial neural network (ANN) model to predict surface roughness, cutting force, and temperature during machining of Nimonic-75 and Nicrofer C-263 super alloys. Experiments were conducted to collect input/output data on cutting speed, feed rate, depth of cut, surface roughness, cutting force, and temperature. The ANN model was trained on this data and could accurately model the complex relationships between cutting conditions and output parameters for process analysis and optimization.
Aspects Regarding the Elastic Properties of Silicon and Its Influence on the ...IRJET Journal
This document summarizes research on modeling the elastic properties of silicon and how it influences the behavior of micro-mechanical components like MEMS sensors. Finite element modeling was used to simulate the vibration modes and resonant frequencies of silicon micro-cantilever beams. Silicon was modeled as both an isotropic and orthotropic material using different elastic modulus values from literature. The simulation results were compared to analytical calculations and experimental measurements using laser Doppler vibrometry and atomic force microscopy. Modeling silicon as an orthotropic material with different elastic properties along crystal axes provided the best match to experimental frequency values, with errors less than 3% for bending modes.
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
This document summarizes a study that used the Taguchi method to analyze the effect of parameters like voltage, current, and pulse on time on material removal rate (MRR) and surface roughness (SR) during CNC EDM of SK-5 material. Experiments were conducted based on an L9 orthogonal array with 3 factors at 3 levels. Analysis found voltage had the largest effect on MRR while pulse on time most influenced SR. The optimized parameters were experiment 4 for MRR and experiment 7 for SR. In conclusion, the Taguchi method helped determine the best settings of CNC EDM parameters for machining SK-5.
Optimization of the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
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.
This document summarizes a research study on optimizing parameters for the electrochemical machining process to maximize the material removal rate when machining Hastelloy C-276. The researchers conducted experiments using a Taguchi design of experiments with three machining parameters (feed rate, electrolyte flow rate, and voltage) each set at three levels. The highest material removal rate was achieved at a high feed rate of 1 mm/min, low electrolyte flow rate of 150 L/hr, and high voltage of 16V. Analysis of the results showed that feed rate had the strongest influence on material removal rate, with higher feed rates increasing the rate.
International Journal of Engineering Research and DevelopmentIJERD Editor
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.
EFFECT OF EDM PARAMETERS IN OBTAINING MAXIMUM MRR AND MINIMUM EWR BY MACHININ...IAEME Publication
EDM machining is used for very hard and complex cutting of conducting materials with higher surface finish and close dimensions. EDM process parameters are affected by both electrical and non electrical parameters. In this paper, cutting of hard material Stainless steel 316 is done on electro discharge machine with copper as cutting tool electrode. This paper presents the effect of control factors (i.e., current, pulse on time, pulse off time, fluid pressure) for maximum material
removal rate (MRR) and minimum electrode wear rate (EWR) for die sinking Electric Discharge Machine.
The document describes an experimental study on the effect of vibration on micro-electro-discharge machining (μEDM). Response surface methodology was used to develop mathematical models for material removal rate and tool wear rate based on experiments using a central composite design. Analysis of variance was performed to verify the models. The results show that applying vibration to the workpiece during μEDM can impact process performance characteristics like material removal rate and tool wear rate. The developed models can be used to determine optimal input parameter values for the μEDM drilling process.
The entire research work is experiment oriented and the conclusions are drawn based on
graphical analysis of experimental results. The research work carried out reveals that the findings are
encouraging in establishing the effect of Voltage, Capacitance and work piece vibration Frequency,
amplitude on different materials µEDM drilling process performance characteristics. The results of
this investigations can be adopted in deciding the optimal values of input process parameters µEDM
drilling process
The document describes an experimental study that uses response surface methodology to develop mathematical models for material removal rate (MRR) and tool wear rate (TWR) in micro-electro-discharge machining (μEDM) as functions of voltage, capacitance, and workpiece vibration frequency and amplitude. Central composite design was used to generate experimental data, and analysis of variance was performed to verify the adequacy of the developed models within a given confidence interval. The results provide information on optimizing input process parameters for μEDM drilling.
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
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.
This document discusses an experimental study analyzing the influence of control parameters on material removal rate (MRR) in electrical discharge machining (EDM) using signal-to-noise (S/N) ratio and analysis of variance (ANOVA). Experiments were conducted using different electrode and workpiece materials under varying levels of control parameters including electrode speed, current, and depth of cut. MRR values were measured and S/N ratios were calculated to determine the optimal control parameter settings for maximizing MRR. The results indicate that control parameters have a significant effect on MRR in EDM, and S/N ratio and ANOVA analysis can help identify parameters and levels that improve process performance.
Study of different work materials effect on surface roughness in electrochemi...eSAT Journals
Abstract In today’s manufacturing era, Electrochemical machining process provides good surface finish due to its controlled atomic dissolution of work material, involving chemical reactions during machining. To enhance the machining performance, precise selection of machining parameters, is still a demanding job in ECM process as it is very complex process involving so many unpredictable chemical reactions while machining. Due to chemical and electrical characteristics; effect on surface roughness of process also depends upon the type of material. A very rare work has been done by taking work material as input parameter for experimental study of ECM. The reaction of work material is investigated as an input parameter along with voltage and inter-electrode gap on improvement in surface roughness using orthogonal Array. Work-piece material is discovered as most significant factor influencing improvement in Surface Roughness followed by Inter-electrode gap and Voltage. Effect of ECM is found to be most prominent on Brass work-piece.
Keywords: Electro chemical machining (ECM); Surface roughness (SR); Orthogonal Array; Mild steel; Brass; Aluminium; Taguchi; ANOVA.
This document summarizes a study that used response surface methodology and grey-Taguchi technique to model and optimize the wire electrical discharge machining (WEDM) process. Experiments were conducted varying 6 process parameters (discharge current, pulse duration, etc.) at 3 levels. Models were developed relating the responses of material removal rate, surface finish, and kerf to the parameters. Predicted data from the models were used in a Taguchi design to find the optimal parameter combination for maximizing material removal rate and surface finish while minimizing kerf.
IRJET - Mathematical Modeling and Optimization of Process Parameters for EN31...IRJET Journal
This document summarizes a study that used response surface methodology to develop mathematical models for optimizing process parameters in electrical discharge machining (EDM) of En31 material. Experiments were conducted varying discharge current, voltage, and pulse on time. Material removal rate, tool wear rate, and surface roughness were measured. The goal was to maximize material removal rate and minimize tool wear and surface roughness. Optimum parameters were determined using D-optimal plots and ANOVA. Models developed using Minitab software can predict responses for different process parameters and materials in EDM.
Micron range complex structure in micro electrochemical machining- a revieweSAT Journals
Abstract
The major problem in the micro-manufacturing is concerned with achieving the good dimensional accurate products with the better surface finish, high MRR, no tool wear, absence of stress and no heat-affected zone. Micro-machining proved itself as a promising solution of this major problem. In recent days, industries are regularly looking for fabricating the micro-components which can be able to perform their complex functions in the sensitive areas of electronics, automotive, biomedical and optics. Now a day for miniature components micro-machining plays a very important role, its techniques are excellent to machine any complex shapes with good accuracy and bright surface finish. Material with any value of the hardness can be machined easily with all the offered advantages of micro-machining in the electrochemical micro-machining process (EMM). In this article; review of different methodologies and effect of machining parameters were studied along with different electrolytes; which plays a significant role in electro chemical micro-machining. The objective of this study is to know about the optimum micro-machining parameters for the EMM process and it is also much important to find out the research gap through the different studies. In this study, it has been found out MRR and overcut are depends upon the voltage, electrolyte concentration, IEG, pulse ON/OFF time, pulse duration, pulse frequency, RPM of the tool and flow rate of electrolyte. The proper selections of parameters in EMM are essentials for achieving the overall improvement in the micro-machining operation.
Keywords: Micro-Manufacturing, Micro-Machining, Electrochemical Machining (ECM), Electrochemical Micro-Machining (EMM).
Micron range complex structure in micro electrochemical machining- a revieweSAT Journals
This document provides a review of electrochemical micro-machining (EMM) including 16 studies that investigated various parameters of the EMM process. The studies examined parameters like voltage, electrolyte concentration, tool size, pulse characteristics, and more. The key outputs measured included material removal rate, overcut, surface roughness, hole diameter and depth ratios. EMM is able to machine complex shapes with high accuracy and surface finish without thermal or mechanical stresses.
OPTIMIZATION OF ELECTRODE WEAR RATE ON ELECTRICAL DISCHARGE MACHINING AISI 30...IAEME Publication
AISI 304 stainless steel have a wide range of applications in the industrial field. The need for machining AISI 304 SS has not been eliminated fully. The electrode wear rate (EWR) is an
important aspect during electrical discharge machining (EDM). In this investigation an attempt has been made to assess the factors influencing electrode wear rate on the machining of AISI 304 SS. Design of experiments (full factorial design) concept has been used for experimentation. The machining experiments were conducted on a die sinking EDM machine using two levels of factors.
ELECTRO CHEMICAL MACHINING AND ELECTRICAL DISCHARGE MACHINING PROCESSES MICRO...ijiert bestjournal
Nowadays,necessity of small components is a common trend. These requirements encourage the researcher s to develop very minutest size components to fulfill the demand. The manufact uring of these type of components is a difficult ob ligation and for that various machining methods are develop to manufacture such c omponents. In this article the Electro Chemical mac hining and Electrical Discharge Machining is reviewed. We tried to summar ize the work of various researchers. The study show s that this type of machining processes gives good alternative.
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
Optimization of EDM Process Parameters using Response Surface Methodology for...ijtsrd
The present work demonstrates the optimization process of material removal rate MRR of electrical discharge machining EDM by RSM Response Surface Methodology . The work piece material was EN31 tool steel. The pulse on time, pulse off time, pulse current and voltage were the control parameters of EDM. RSM method was used to design the experiment using rotatable central composite design as this is the most widely used experimental design for modeling a second–order response surface. The process has been successfully modeled using response surface methodology RSM and model adequacy checking is also carried out using Minitab software. The second order response models have been validated with analysis of variance. Finally, an attempt has been made to estimate the optimum machining conditions to produce the best possible responses within the experimental constraints. Dr. N. Mahesh Kumar | Mr. P. Chinna Rao ""Optimization of EDM Process Parameters using Response Surface Methodology for AISI D3 Steel"" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23535.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23535/optimization-of-edm-process-parameters-using-response-surface-methodology-for-aisi-d3-steel/dr-n-mahesh-kumar
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.
This document discusses using the Taguchi method to optimize WEDM parameters for machining EN 31 steel to achieve lower surface roughness. An experiment was conducted using an L9 orthogonal array to test different levels of pulse on time, pulse off time, gap voltage, and wire feed. Analysis of variance showed that pulse on time had the largest effect on surface roughness at 48.84%, followed by gap voltage at 36.81%. Confirmation experiments found that the optimized parameters of 4μs pulse on time, 6μs pulse off time, 40V gap voltage, and 4mm/min wire feed achieved a predicted surface roughness with only 11.5% error, validating the model. The Taguchi method was able to effectively optimize
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