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.
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.
This document provides a review of recent developments in electrochemical machining (ECM) and electrical discharge machining (EDM). ECM and EDM are important machining processes that can machine difficult materials like metals, alloys, and composites. The document summarizes advances in modeling and simulation of ECM processes, process monitoring and control techniques, machining capabilities including high aspect ratio microstructures, use of different electrolytes, and development of microtools. It also briefly discusses emerging areas like nano-electro machining and hybrid processes combining ECM with other techniques.
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
This document summarizes a study on the influence of electrochemical machining (ECM) process parameters on material removal rate (MRR) and surface roughness when machining stainless steel SS 304. Experiments were conducted using a Taguchi design of experiments approach to determine the effects of time, voltage, current, electrolyte concentration, feed rate, and pressure. Results showed that MRR increased with increasing voltage, electrolyte concentration, time, and feed rate, but irregularly increased with high currents. Surface roughness decreased with increasing current, and time was the most influential parameter on surface finish. The experimental setup and ECM process characteristics are also described.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
This document summarizes research that used response surface methodology to optimize the electrical discharge machining (EDM) process parameters when machining SCM420 low alloy steel. The researchers investigated the effects of peak current, pulse on time, and gap voltage on material removal rate (MRR) and surface roughness (Ra). They conducted experiments according to a central composite design and analyzed the results to develop mathematical models relating the process parameters to the output responses. The analysis found that peak current had the greatest influence on both MRR and Ra, with MRR increasing and Ra decreasing at higher peak current levels. Optimal values for the process parameters to achieve high MRR and low Ra were determined to be a peak current of 22 amps, pulse
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
MULTI RESPONSE OPTIMISATION OF DIE SINKER EDM FOR ALSIC COMPOSITE IAEME Publication
On e of the important aspects that should be taken into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM) is the correct selection of manufacturing conditions. Appropriate choice of the machining parameters and electrode material during electric discharge machining is fundamental to its performance and accuracy.
This document describes an experimental study that evaluated the material stability of different aluminum alloys for ultra precision applications. Specifically, it tested 7075-T7351, 7075-T6 and 6061-T6 aluminum alloys under cyclic loading conditions. The study used a custom test machine with sensors to precisely measure deformation in the aluminum alloy samples. Results showed that the different alloys exhibited inelastic and plastic deformation under loading and unloading cycles. Inelastic deformation recovered after unloading, while plastic deformation remained. The document aims to determine the most suitable aluminum alloy to replace steel components in high frequency weighing scales.
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.
This document provides a review of recent developments in electrochemical machining (ECM) and electrical discharge machining (EDM). ECM and EDM are important machining processes that can machine difficult materials like metals, alloys, and composites. The document summarizes advances in modeling and simulation of ECM processes, process monitoring and control techniques, machining capabilities including high aspect ratio microstructures, use of different electrolytes, and development of microtools. It also briefly discusses emerging areas like nano-electro machining and hybrid processes combining ECM with other techniques.
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
This document summarizes a study on the influence of electrochemical machining (ECM) process parameters on material removal rate (MRR) and surface roughness when machining stainless steel SS 304. Experiments were conducted using a Taguchi design of experiments approach to determine the effects of time, voltage, current, electrolyte concentration, feed rate, and pressure. Results showed that MRR increased with increasing voltage, electrolyte concentration, time, and feed rate, but irregularly increased with high currents. Surface roughness decreased with increasing current, and time was the most influential parameter on surface finish. The experimental setup and ECM process characteristics are also described.
Optimization of Electrical Discharge Machining Process Parameters using SCM42...IOSRJMCE
This document summarizes research that used response surface methodology to optimize the electrical discharge machining (EDM) process parameters when machining SCM420 low alloy steel. The researchers investigated the effects of peak current, pulse on time, and gap voltage on material removal rate (MRR) and surface roughness (Ra). They conducted experiments according to a central composite design and analyzed the results to develop mathematical models relating the process parameters to the output responses. The analysis found that peak current had the greatest influence on both MRR and Ra, with MRR increasing and Ra decreasing at higher peak current levels. Optimal values for the process parameters to achieve high MRR and low Ra were determined to be a peak current of 22 amps, pulse
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
MULTI RESPONSE OPTIMISATION OF DIE SINKER EDM FOR ALSIC COMPOSITE IAEME Publication
On e of the important aspects that should be taken into consideration in the majority of manufacturing processes and, particularly, in processes related to Electrical Discharge Machining (EDM) is the correct selection of manufacturing conditions. Appropriate choice of the machining parameters and electrode material during electric discharge machining is fundamental to its performance and accuracy.
This document describes an experimental study that evaluated the material stability of different aluminum alloys for ultra precision applications. Specifically, it tested 7075-T7351, 7075-T6 and 6061-T6 aluminum alloys under cyclic loading conditions. The study used a custom test machine with sensors to precisely measure deformation in the aluminum alloy samples. Results showed that the different alloys exhibited inelastic and plastic deformation under loading and unloading cycles. Inelastic deformation recovered after unloading, while plastic deformation remained. The document aims to determine the most suitable aluminum alloy to replace steel components in high frequency weighing scales.
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This document discusses predicting optimized EDM machining parameters through thermo-mechanical analysis. It begins with an abstract that outlines the goal of determining optimal machining parameters to maximize material removal rate in EDM of OHNS die steel. It then reviews relevant literature on thermal modeling and optimization of EDM processes. The problem statement indicates the challenges of determining optimal pulse duration, peak current, and voltage to increase material removal rate cost-effectively. The objectives are presented as determining parameters to maximize material removal rate and improve surface integrity of machined workpieces. Finally, the theoretical analysis section outlines the numerical modeling approach using finite element analysis and Joshi and Pande's thermal model of EDM sparks.
THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS OF MATERIAL EN-31 IN...ijiert bestjournal
The paper represent the work done for making mathematical models fo r analysis of the effects of machining parameters on the performance characteristics in EDM process of Alloy steel (EN-31). The mathematical models are developed using the response surface methodology (RSM) to explai n the influences of machining parameters on the performance characteristics in the EDM process.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
IRJET- Parametric Optimization of Powder Mixed Electronic Discharge Machine.IRJET Journal
The document summarizes a study that optimized the process parameters of powder mixed electrical discharge machining (PMEDM) to maximize material removal rate and minimize tool wear rate and surface roughness. Key parameters investigated included peak current, pulse on time, and aluminum powder concentration. Experiments were designed using Taguchi methodology and analyzed in MINITAB 18 software. The results showed that peak current had the greatest influence on material removal rate, while aluminum powder concentration had the greatest influence on tool wear rate and surface roughness. Recommended optimal parameter settings were determined through confirmation experiments.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
IRJET- Optimization of WEDM Process Parameters on Machining of AA6082/SiC Met...IRJET Journal
This document discusses optimizing the wire electrical discharge machining (WEDM) process parameters for machining an aluminum AA6082/silicon carbide (SiC) metal matrix composite. The objectives are to achieve the maximum material removal rate and minimum surface roughness. A Taguchi L9 orthogonal array experimental design is used to evaluate three process parameters (pulse on time, pulse off time, and peak current) at three levels each. The experiments are conducted on an AA6082/5% SiC composite fabricated using stir casting. Response variables of material removal rate and surface roughness are measured and multi-objective optimization is performed using Grey relational analysis.
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.
Review Article on Machining of Nickel-Based Super Alloys by Electric Discharg...sushil Choudhary
Electric discharge machining (EDM) process generally used for burrs free, less metallurgical damage, stress free and very precise machining and produces mould cavity, deep holes, complex shapes & size by arc erosion in all types of electro-conductive materials. In this process, the metal is removed from the work piece due to erosion caused by rapidly recurring spark discharge taking place between the tool electrode and work-piece. Tool electrode and wok-piece both submersed into the dielectric fluid. The main aims of this review paper work is to present the consolidated information about the contribution of various researchers on the machining applications of electric discharge machining process on Nickel-Base Super alloys materials, utilization of various tool and techniques for correlating experiment results and applications of product through the EDM. Nickel-Base Super alloys materials is widely used for fuel tanks, aircraft & rocket engine components, nuclear fuel element spacers, casings, fasteners, rings, seal, measuring instrument, cryogenic storage tanks and automobile components etc.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
Machinability evaluation of cryogenically tempered die steel in electric disc...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
This document discusses using a back propagation neural network (BPNN) to predict carbon monoxide (CO) emissions from a diesel engine. It begins by providing background on BPNN and how it was applied in this study. Experimental data on engine parameters and CO emissions were collected from tests. The data were divided into training and testing sets to train and validate the BPNN. Different combinations of engine parameters were used as inputs to the BPNN in various "strategies" to determine the best parameters for accurately predicting CO emissions. The BPNN architecture and training parameters were optimized to minimize error between predicted and actual CO emissions. The goal was to develop a method for predicting emissions to better control engine parameters and reduce pollution.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Gray Relational Basedanalysis of Tool SteelIRJET Journal
This document presents research on optimizing the electro discharge machining (EDM) process for tool steel using Taguchi methods and grey relational analysis. The researchers conducted experiments with tool steel as the workpiece material and copper as the electrode. Response variables included material removal rate (MRR) and surface roughness (Ra). Taguchi methods were used to design the experiments and orthogonal arrays. Grey relational analysis was then used to analyze the multiple responses and determine the optimal process parameters. The analysis involved normalizing the experimental data, calculating grey relational coefficients and grades, and analyzing the results using ANOVA to select parameters that maximize MRR and minimize Ra.
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.
Engineering Research Publication
Best International Journals, High Impact Journals,
International Journal of Engineering & Technical Research
ISSN : 2321-0869 (O) 2454-4698 (P)
www.erpublication.org
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
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by electrochemical dissolution rather than mechanical forces. ECM was first introduced in 1929 and has since been used for complex machining applications. In the ECM process, an electric current is applied between an electrode tool and a conductive workpiece submerged in an electrolyte solution. This causes metal ions from the workpiece to dissolve into the solution, machining the workpiece without generating mechanical forces or heat. ECM can machine hard metals and complex shapes more accurately than traditional methods and is used for applications in industries like aerospace, electronics, and automotive.
Electrical discharge machining of the composites a literature revieweSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This document discusses predicting optimized EDM machining parameters through thermo-mechanical analysis. It begins with an abstract that outlines the goal of determining optimal machining parameters to maximize material removal rate in EDM of OHNS die steel. It then reviews relevant literature on thermal modeling and optimization of EDM processes. The problem statement indicates the challenges of determining optimal pulse duration, peak current, and voltage to increase material removal rate cost-effectively. The objectives are presented as determining parameters to maximize material removal rate and improve surface integrity of machined workpieces. Finally, the theoretical analysis section outlines the numerical modeling approach using finite element analysis and Joshi and Pande's thermal model of EDM sparks.
THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS OF MATERIAL EN-31 IN...ijiert bestjournal
The paper represent the work done for making mathematical models fo r analysis of the effects of machining parameters on the performance characteristics in EDM process of Alloy steel (EN-31). The mathematical models are developed using the response surface methodology (RSM) to explai n the influences of machining parameters on the performance characteristics in the EDM process.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
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.
Modeling and optimization of edm process parameters a reviewIAEME Publication
This document provides a review of research on modeling and optimization of electrical discharge machining (EDM) process parameters. It summarizes 22 research papers that developed mathematical models and applied optimization techniques like response surface methodology, Taguchi method, and genetic algorithms to determine optimal process parameters. The parameters studied include current, pulse on/off time, voltage, and material/electrode properties. The goals of optimization were to improve material removal rate, reduce tool wear and surface roughness. Modeling helped establish relationships between input and output parameters for better process control and performance.
IRJET- Parametric Optimization of Powder Mixed Electronic Discharge Machine.IRJET Journal
The document summarizes a study that optimized the process parameters of powder mixed electrical discharge machining (PMEDM) to maximize material removal rate and minimize tool wear rate and surface roughness. Key parameters investigated included peak current, pulse on time, and aluminum powder concentration. Experiments were designed using Taguchi methodology and analyzed in MINITAB 18 software. The results showed that peak current had the greatest influence on material removal rate, while aluminum powder concentration had the greatest influence on tool wear rate and surface roughness. Recommended optimal parameter settings were determined through confirmation experiments.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
IRJET- Optimization of WEDM Process Parameters on Machining of AA6082/SiC Met...IRJET Journal
This document discusses optimizing the wire electrical discharge machining (WEDM) process parameters for machining an aluminum AA6082/silicon carbide (SiC) metal matrix composite. The objectives are to achieve the maximum material removal rate and minimum surface roughness. A Taguchi L9 orthogonal array experimental design is used to evaluate three process parameters (pulse on time, pulse off time, and peak current) at three levels each. The experiments are conducted on an AA6082/5% SiC composite fabricated using stir casting. Response variables of material removal rate and surface roughness are measured and multi-objective optimization is performed using Grey relational analysis.
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.
Review Article on Machining of Nickel-Based Super Alloys by Electric Discharg...sushil Choudhary
Electric discharge machining (EDM) process generally used for burrs free, less metallurgical damage, stress free and very precise machining and produces mould cavity, deep holes, complex shapes & size by arc erosion in all types of electro-conductive materials. In this process, the metal is removed from the work piece due to erosion caused by rapidly recurring spark discharge taking place between the tool electrode and work-piece. Tool electrode and wok-piece both submersed into the dielectric fluid. The main aims of this review paper work is to present the consolidated information about the contribution of various researchers on the machining applications of electric discharge machining process on Nickel-Base Super alloys materials, utilization of various tool and techniques for correlating experiment results and applications of product through the EDM. Nickel-Base Super alloys materials is widely used for fuel tanks, aircraft & rocket engine components, nuclear fuel element spacers, casings, fasteners, rings, seal, measuring instrument, cryogenic storage tanks and automobile components etc.
An Experimental Investigation of Material Removal Rate on H-13 Die Tool Steel...Dr. Amarjeet Singh
H-13 is die tool steel, it have widely applications in the Hot punches and dies for blanking, bending, swaging and forging, Hot extrusion dies for aluminum, cores, ejector pins, inserts, Nozzles for aluminum, tin and lead die casting, Hot shear blades etc. as the H-13 steel has widely applications so it is chosen for the present study. Presents works shows the effect of various process parameters like peak current, Pulse on Time and Feed rate on Material Removal Rate. EDM Drilling and Taguchi technique is used for the optimization of response variables.
Machinability evaluation of cryogenically tempered die steel in electric disc...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
This document discusses using a back propagation neural network (BPNN) to predict carbon monoxide (CO) emissions from a diesel engine. It begins by providing background on BPNN and how it was applied in this study. Experimental data on engine parameters and CO emissions were collected from tests. The data were divided into training and testing sets to train and validate the BPNN. Different combinations of engine parameters were used as inputs to the BPNN in various "strategies" to determine the best parameters for accurately predicting CO emissions. The BPNN architecture and training parameters were optimized to minimize error between predicted and actual CO emissions. The goal was to develop a method for predicting emissions to better control engine parameters and reduce pollution.
A Literature Review on Effect of Machining Parameters in Wire - EDMijsrd.com
The recent upgradation of newer and harder materials has made the machining task in WEDM quite challenging. Thus for the optimum use of all the resources it is essential to make the optimum use of parameters to get the best output to increase the productivity. Advances in technology have impacted with an increased cutting speed and tight tolerances in WEDM. This paper reviews the various notable works in field of WEDM and magnifies on effect of machining parameters on MRR, kerf width and surface roughness.
Gray Relational Basedanalysis of Tool SteelIRJET Journal
This document presents research on optimizing the electro discharge machining (EDM) process for tool steel using Taguchi methods and grey relational analysis. The researchers conducted experiments with tool steel as the workpiece material and copper as the electrode. Response variables included material removal rate (MRR) and surface roughness (Ra). Taguchi methods were used to design the experiments and orthogonal arrays. Grey relational analysis was then used to analyze the multiple responses and determine the optimal process parameters. The analysis involved normalizing the experimental data, calculating grey relational coefficients and grades, and analyzing the results using ANOVA to select parameters that maximize MRR and minimize Ra.
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.
Engineering Research Publication
Best International Journals, High Impact Journals,
International Journal of Engineering & Technical Research
ISSN : 2321-0869 (O) 2454-4698 (P)
www.erpublication.org
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
IRJET- Effects of Process Parameters in Wire Cut EDM on Material Removal Rate...IRJET Journal
This document summarizes a study that investigated the effects of process parameters in wire cut electrical discharge machining (WEDM) on the material removal rate of aluminum composite materials. Experiments were conducted varying parameters like pulse on time, pulse off time, servo voltage, and wire speed. It was found that material removal rate increased with increasing pulse on time and decreased with increasing pulse off time and servo voltage. The optimal set of parameters to maximize material removal rate was also determined.
Electrochemical machining (ECM) is a non-traditional machining process that removes metal by electrochemical dissolution rather than mechanical forces. ECM was first introduced in 1929 and has since been used for complex machining applications. In the ECM process, an electric current is applied between an electrode tool and a conductive workpiece submerged in an electrolyte solution. This causes metal ions from the workpiece to dissolve into the solution, machining the workpiece without generating mechanical forces or heat. ECM can machine hard metals and complex shapes more accurately than traditional methods and is used for applications in industries like aerospace, electronics, and automotive.
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).
Investigation on electrochemical discharge machining of fibre compositesGolam Kibria
The document summarizes an investigation into electrochemical discharge machining (ECDM) of fiber composites. It discusses how ECDM can effectively machine composites like glass fiber reinforced plastics to achieve good surface finish and accuracy. Experiments were conducted drilling holes in GFRP samples using varying voltages, electrolyte concentrations, and inter-electrode gaps. Results showed that material removal rate was highest at 55V, 20% electrolyte concentration, and 20mm gap, while tool wear rate increased with voltage and electrolyte concentration. Photomicrographs supported that ECDM can machine composites without fiber damage when using optimal parameters.
This document discusses electrochemical discharge machining (ECDM), which combines electrochemical machining (ECM) and electric discharge machining (EDM) to machine hard and brittle non-conductive materials like glass, quartz, and ceramics. It provides an introduction to ECDM, describes the working principle involving thermal and chemical material removal, lists the main subsystems of an ECDM setup, and compares ECDM to ECM and EDM in terms of material removal rate, accuracy, surface finish, and other factors. Key application areas of ECDM include micro-holes, grooves, and complex shapes in non-conductive materials for industries like turbines, filters, electronics, and
Electro-chemical machining (ECM) is a non-traditional machining process that removes metal by dissolving it in an electrolyte with the use of electric current. In ECM, the workpiece acts as an anode and is dissolved by the electrolyte, while a tool with the desired shape acts as a cathode. Key factors in ECM include the electrolyte, which carries current and removes dissolved material, the tool and workpiece materials, and a DC power supply. ECM can machine hard metals and complex shapes with high accuracy and no tool wear. Common applications of ECM include machining turbine blades, aerospace components, and other difficult-to-machine metals.
Electrochemical Machining (ECM) has established itself as one of the major alternatives to conventional methods of machining difficult - to - cut materials of and generating complex contours, without inducing residual stress and tool wear.
This seminar is devoted to the study of influences of variable ECM parameters like applied voltage and feed rate keeping other parameters constant on the surface roughness (Ra) using Response Surface Methodology (RSM).
An Electrode Shape Configuration on the Performance of Die Sinking Electric D...IJERA Editor
Electrical discharge machining (EDM) is one of the non-traditional machining processes, based on thermo electric energy
between the work piece and an electrode. In this process, the material removal is occurred electro thermally by a series of
successive discrete discharges between electrode and the work piece. The parametric analysis of the EDM process by using
different electrode shapes has been carried out. This Research discusses the performance of die sinking EDM due to the
shape configuration of the electrode. The effect of electrode shapes configuration on the performance of die sinking electric
discharge machine has been carried out. The optimization of the parameters of the EDM machining has been carried out by
using the taguchi‟s method for design of experiments (DOE). In this research we have used taguchi‟s method for design of
experiments with three input parameters and their three levels of experiments. The dielectric used is kerosene diluted with
water. The objective of the analysis is to optimize the process parameters of EDM with the help of taguchi method and using
Minitab software.
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
Influence of process parameters on MRR in EDM of AISI D2 Steel: a RSM approachMohan Kumar Pradhan
Response Surface Methodology (RSM) is used to investigate the
effect of three controllable input variables namely: discharge current, pulse duration,
and pulse off time on material removal rate (MRR) in EDM process. To study the
proposed second-order polynomial model for MRR, a central composite design is
used to estimation the model coefficients of the three factors, which are believed to
influence the MRR in EDM process. Experiments were conducted on AISI D2 tool
steel with copper electrode. The response is modeled using RSM on the experimental
data. The significant coefficients are obtained by performing analysis of variance
(ANOVA) at 5% level of significance. It is found that discharge current, pulse duration,
and pulse off time and few of their interactions have significant effect on the MRR.
The model sufficiency is very satisfactory as the coefficient of determination (R2) is
found to be 97.6%.
Optimization of MRR and SR by employing Taguchis and ANOVA method in EDMIRJET Journal
The document describes research into optimizing material removal rate (MRR) and surface roughness (SR) in electric discharge machining (EDM). Experiments were conducted with four machining parameters (discharge current, source voltage, pulse-on time, and pulse-off time) at different levels using a Taguchi design of experiments approach. Analysis of variance (ANOVA) found that discharge current contributed most to MRR at 33.33%, while pulse-on time contributed most to SR at 30.62%. The study aims to apply Taguchi and ANOVA methods to optimize MRR and SR in EDM.
Study of surface roughness for discontinuous ultrasonic vibration assisted el...eSAT Journals
Abstract The objective of this paper is to study the effects of response parameters on the performance characteristics in the Ultrasonic vibration Assisted Electric Discharge Machining (UEDM) Process. Response Surface Methodology (RSM) is used to investigate the effect of amplitude of vibration, peak current, pulse on-time, machining time and flushing pressure. To study the proposed second order polynomial model for surface roughness (SR), a Central Composite Design (CCD) is used for the estimation of the model coefficients of five factors, which are believed to influence the SR in UEDM process. Experiments are conducted on Aluminum alloy 6063 with copper electrode. The response is modeled on experimental data by using RSM. The separable influence of individual machining parameters and the interaction between these parameters are also investigated by using analysis of variance (ANOVA). It is found that amplitude of vibration, peak current; pulse-on time, flushing pressure and most of their interactions have significant affect on SR. Keywords: Central Composite Design, SR, UEDM, RSM, Aluminum alloy (Al6063)
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
IRJET- A Review Study of Thermal Electrical Model using ANSYS SoftwareIRJET Journal
This document summarizes a research study that used ANSYS software to design a thermal-electrical model for sparks generated during electrical discharge machining (EDM) and determine temperature distribution. The study aimed to model the EDM process, predict maximum temperature, and estimate material removal rate from the workpiece. Experiments were conducted using different pulse on-times and currents on an EN-19 workpiece. Results showed that material removal rate increased with higher current and pulse on-time, and was in agreement with finite element analysis results. The temperature distribution curve was also able to estimate the maximum material removal rate.
Relevance vector machine based prediction of mrrand sr for electro chemical m...iaemedu
This document discusses using a relevance vector machine (RVM) model to predict material removal rate (MRR) and surface roughness (SR) in an electrochemical machining (ECM) process. Experiments were conducted using an EN19 tool steel workpiece and varying the flow rate of electrolyte, voltage, and feed rate according to a Taguchi design. An RVM model was developed using these input parameters to predict MRR and SR. The model performance was evaluated by comparing predicted and experimental outputs, with the goal of minimizing regression error. Results showed the RVM model with a Laplace kernel function produced the lowest regression error, indicating it can accurately predict MRR and SR for the ECM process.
Relevance vector machine based prediction of mrrand sr for electro chemical m...IAEME Publication
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 the ECM process outputs.
Relevance vector machine based prediction of mrrand sr for electro chemical m...iaemedu
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.
A review paper on Optimization of process parameter of EDM for air hardening ...IJERA Editor
EDM is now more economical non convectional machining process. It is used widely used on small scale as well major industries. EDM process is affect by so many process parameter which are electrical and non electrical. In this project work the rotating tool is used to improve the Metal removal rate (MRR) and to observe its effect on surface finish. I am using Taguchi’s method as a design of experiments and response surface methodology for analysis and optimization. The machining parameters selected as a variables are pulse off time, pulse on time, servo voltage. The output measurement include MRR and surface roughness.
PARAMETRIC OPTIMIZATION OF ELECTROCHEMICAL MACHININGAnmol Mangat
1. The document discusses parametric optimization of electrochemical machining (ECM). ECM is a non-traditional machining process that removes metal through reverse electroplating. It can machine hard metals and complex geometries.
2. The author designs and fabricates an ECM machine to surface finish cylindrical workpieces. Experiments are conducted to analyze the effect of voltage, time, and revolutions per minute on surface finish improvement percentage.
3. A relationship between process parameters and output characteristics is developed using a design of experiment approach to optimize the ECM process for improving surface finish.
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.
IRJET-Experimental Analysis Optimization of Process Parameters of Wire EDM on...IRJET Journal
This document analyzes the optimization of process parameters for wire electrical discharge machining (WEDM) of stainless steel 316L. It conducts experiments using different controllable factors like discharge current, pulse on/off time, and arc gap. Taguchi design of experiments is used to optimize for maximum material removal rate. Experiments are conducted using a copper tool on 316L stainless steel workpieces. The results are analyzed to determine the optimum parameter levels for achieving higher material removal rate and better surface finish quality during WEDM of 316L stainless steel.
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.
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.
Literature Review on Electrical Discharge Machining (EDM)
Research Paper Published by:
Vishal Kumar Jaiswal
M.Tech (Production and Industrial Engineering)
Paper Source:
http://ijsrd.com/articles/IJSRDV6I50167.pdf
http://ijsrd.com/Article.php?manuscript=IJSRDV6I50167
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.
Machinability evaluation of cryogenically tempered die steel in electric disc...eSAT Journals
Abstract Electrical discharge drilling (EDD) is a well-known machining alternative for creating geometrically obscure shapes in die steel. Cryogenic temper of work and electrode material is innovative technology in the field of EDD. Work in hand investigates the effect of cryogenic tempering of AISI D2 steel (workpiece) and copper electrode (tool) on material removal rate (MRR) in EDD based on design of experiments approach. The discharge current, pulse-on-time and electrode-workpiece combination (cryogenically tempered or untempered) are the parameters selected for this study. The orthogonal array, signal-to-noise ratio (S/N) and analysis of variance (ANOVA) are used to find out the effect of cryogenic tempering on MRR. The results obtained demonstrate that the discharge current and pulse-on-time are the major parameters influencing the MRR for all samples, followed by electrode-workpiece combination i.e. cryogenic tempering of electrode and workpiece. Cryogenic tempering is found to have significant effect (nearly 10%) on MRR. It is recommended to cryogenically temper both the electrode and workpiece to maximize the MRR. Index Terms: Electric discharge drilling, Cryogenic tempering, Die steel, copper electrode
This document is a project report submitted to Gujarat Technological University for their undergraduate program. It examines the experimental study of the effect of process parameters on the performance of electrical discharge machining (EDM). The project was conducted by four students under the guidance of a professor from the Mechanical Engineering department. The report includes certificates from the guide and examiners. It also acknowledges the help received. The abstract provides an overview of the focus of the project which is to analyze how current, voltage, pulse-on time and pulse-off time affect the material removal rate of the EDM process. The literature review covers past research conducted on improving the speed and accuracy of EDM as well as applying it to new materials.
Similar to Study of different work materials effect on surface roughness in electrochemical machining process (20)
Mechanical properties of hybrid fiber reinforced concrete for pavementseSAT Journals
Abstract
The effect of addition of mono fibers and hybrid fibers on the mechanical properties of concrete mixture is studied in the present
investigation. Steel fibers of 1% and polypropylene fibers 0.036% were added individually to the concrete mixture as mono fibers and
then they were added together to form a hybrid fiber reinforced concrete. Mechanical properties such as compressive, split tensile and
flexural strength were determined. The results show that hybrid fibers improve the compressive strength marginally as compared to
mono fibers. Whereas, hybridization improves split tensile strength and flexural strength noticeably.
Keywords:-Hybridization, mono fibers, steel fiber, polypropylene fiber, Improvement in mechanical properties.
Material management in construction – a case studyeSAT Journals
Abstract
The objective of the present study is to understand about all the problems occurring in the company because of improper application
of material management. In construction project operation, often there is a project cost variance in terms of the material, equipments,
manpower, subcontractor, overhead cost, and general condition. Material is the main component in construction projects. Therefore,
if the material management is not properly managed it will create a project cost variance. Project cost can be controlled by taking
corrective actions towards the cost variance. Therefore a methodology is used to diagnose and evaluate the procurement process
involved in material management and launch a continuous improvement was developed and applied. A thorough study was carried
out along with study of cases, surveys and interviews to professionals involved in this area. As a result, a methodology for diagnosis
and improvement was proposed and tested in selected projects. The results obtained show that the main problem of procurement is
related to schedule delays and lack of specified quality for the project. To prevent this situation it is often necessary to dedicate
important resources like money, personnel, time, etc. To monitor and control the process. A great potential for improvement was
detected if state of the art technologies such as, electronic mail, electronic data interchange (EDI), and analysis were applied to the
procurement process. These helped to eliminate the root causes for many types of problems that were detected.
Managing drought short term strategies in semi arid regions a case studyeSAT Journals
Abstract
Drought management needs multidisciplinary action. Interdisciplinary efforts among the experts in various fields of the droughts
prone areas are helpful to achieve tangible and permanent solution for this recurring problem. The Gulbarga district having the total
area around 16, 240 sq.km, and accounts 8.45 per cent of the Karnataka state area. The district has been situated with latitude 17º 19'
60" North and longitude of 76 º 49' 60" east. The district is situated entirely on the Deccan plateau positioned at a height of 300 to
750 m above MSL. Sub-tropical, semi-arid type is one among the drought prone districts of Karnataka State. The drought
management is very important for a district like Gulbarga. In this paper various short term strategies are discussed to mitigate the
drought condition in the district.
Keywords: Drought, South-West monsoon, Semi-Arid, Rainfall, Strategies etc.
Life cycle cost analysis of overlay for an urban road in bangaloreeSAT Journals
Abstract
Pavements are subjected to severe condition of stresses and weathering effects from the day they are constructed and opened to traffic
mainly due to its fatigue behavior and environmental effects. Therefore, pavement rehabilitation is one of the most important
components of entire road systems. This paper highlights the design of concrete pavement with added mono fibers like polypropylene,
steel and hybrid fibres for a widened portion of existing concrete pavement and various overlay alternatives for an existing
bituminous pavement in an urban road in Bangalore. Along with this, Life cycle cost analyses at these sections are done by Net
Present Value (NPV) method to identify the most feasible option. The results show that though the initial cost of construction of
concrete overlay is high, over a period of time it prove to be better than the bituminous overlay considering the whole life cycle cost.
The economic analysis also indicates that, out of the three fibre options, hybrid reinforced concrete would be economical without
compromising the performance of the pavement.
Keywords: - Fatigue, Life cycle cost analysis, Net Present Value method, Overlay, Rehabilitation
Laboratory studies of dense bituminous mixes ii with reclaimed asphalt materialseSAT Journals
Abstract
The issue of growing demand on our nation’s roadways over that past couple of decades, decreasing budgetary funds, and the need to
provide a safe, efficient, and cost effective roadway system has led to a dramatic increase in the need to rehabilitate our existing
pavements and the issue of building sustainable road infrastructure in India. With these emergency of the mentioned needs and this
are today’s burning issue and has become the purpose of the study.
In the present study, the samples of existing bituminous layer materials were collected from NH-48(Devahalli to Hassan) site.The
mixtures were designed by Marshall Method as per Asphalt institute (MS-II) at 20% and 30% Reclaimed Asphalt Pavement (RAP).
RAP material was blended with virgin aggregate such that all specimens tested for the, Dense Bituminous Macadam-II (DBM-II)
gradation as per Ministry of Roads, Transport, and Highways (MoRT&H) and cost analysis were carried out to know the economics.
Laboratory results and analysis showed the use of recycled materials showed significant variability in Marshall Stability, and the
variability increased with the increase in RAP content. The saving can be realized from utilization of recycled materials as per the
methodology, the reduction in the total cost is 19%, 30%, comparing with the virgin mixes.
Keywords: Reclaimed Asphalt Pavement, Marshall Stability, MS-II, Dense Bituminous Macadam-II
Laboratory investigation of expansive soil stabilized with natural inorganic ...eSAT Journals
This document summarizes a study on stabilizing expansive black cotton soil with the natural inorganic stabilizer RBI-81. Laboratory tests were conducted to evaluate the effect of RBI-81 on the soil's engineering properties. The tests showed that with 2% RBI-81 and 28 days of curing, the unconfined compressive strength increased by around 250% and the CBR value improved by approximately 400% compared to the untreated soil. Overall, the study found that RBI-81 effectively improved the strength properties of the black cotton soil and its suitability as a soil stabilizer was supported.
Influence of reinforcement on the behavior of hollow concrete block masonry p...eSAT Journals
Abstract
Reinforced masonry was developed to exploit the strength potential of masonry and to solve its lack of tensile strength. Experimental
and analytical studies have been carried out to investigate the effect of reinforcement on the behavior of hollow concrete block
masonry prisms under compression and to predict ultimate failure compressive strength. In the numerical program, three dimensional
non-linear finite elements (FE) model based on the micro-modeling approach is developed for both unreinforced and reinforced
masonry prisms using ANSYS (14.5). The proposed FE model uses multi-linear stress-strain relationships to model the non-linear
behavior of hollow concrete block, mortar, and grout. Willam-Warnke’s five parameter failure theory has been adopted to model the
failure of masonry materials. The comparison of the numerical and experimental results indicates that the FE models can successfully
capture the highly nonlinear behavior of the physical specimens and accurately predict their strength and failure mechanisms.
Keywords: Structural masonry, Hollow concrete block prism, grout, Compression failure, Finite element method,
Numerical modeling.
Influence of compaction energy on soil stabilized with chemical stabilizereSAT Journals
This document summarizes a study on the influence of compaction energy on soil stabilized with a chemical stabilizer. Laboratory tests were conducted on locally available loamy soil treated with a patented polymer liquid stabilizer and compacted at four different energy levels. The study found that increasing the compaction effort increased the density of both untreated and treated soil, but the rate of increase was lower for stabilized soil. Treating the soil with the stabilizer improved its unconfined compressive strength and resilient modulus, and reduced accumulated plastic strain, with these properties further improved by higher compaction efforts. The stabilized soil exhibited strength and performance benefits compared to the untreated soil.
Geographical information system (gis) for water resources managementeSAT Journals
This document describes a hydrological framework developed in the form of a Hydrologic Information System (HIS) to meet the information needs of various government departments related to water management in a state. The HIS consists of a hydrological database coupled with tools for collecting and analyzing spatial and non-spatial water resources data. It also incorporates a hydrological model to indirectly assess water balance components over space and time. A web-based GIS portal was created to allow users to access and visualize the hydrological data, as well as outputs from the SWAT hydrological model. The framework is intended to facilitate integrated water resources planning and management across different administrative levels.
Forest type mapping of bidar forest division, karnataka using geoinformatics ...eSAT Journals
Abstract
The study demonstrate the potentiality of satellite remote sensing technique for the generation of baseline information on forest types
including tree plantation details in Bidar forest division, Karnataka covering an area of 5814.60Sq.Kms. The Total Area of Bidar
forest division is 5814Sq.Kms analysis of the satellite data in the study area reveals that about 84% of the total area is Covered by
crop land, 1.778% of the area is covered by dry deciduous forest, 1.38 % of mixed plantation, which is very threatening to the
environmental stability of the forest, future plantation site has been mapped. With the use of latest Geo-informatics technology proper
and exact condition of the trees can be observed and necessary precautions can be taken for future plantation works in an appropriate
manner
Keywords:-RS, GIS, GPS, Forest Type, Tree Plantation
Factors influencing compressive strength of geopolymer concreteeSAT Journals
Abstract
To study effects of several factors on the properties of fly ash based geopolymer concrete on the compressive strength and also the
cost comparison with the normal concrete. The test variables were molarities of sodium hydroxide(NaOH) 8M,14M and 16M, ratio of
NaOH to sodium silicate (Na2SiO3) 1, 1.5, 2 and 2.5, alkaline liquid to fly ash ratio 0.35 and 0.40 and replacement of water in
Na2SiO3 solution by 10%, 20% and 30% were used in the present study. The test results indicated that the highest compressive
strength 54 MPa was observed for 16M of NaOH, ratio of NaOH to Na2SiO3 2.5 and alkaline liquid to fly ash ratio of 0.35. Lowest
compressive strength of 27 MPa was observed for 8M of NaOH, ratio of NaOH to Na2SiO3 is 1 and alkaline liquid to fly ash ratio of
0.40. Alkaline liquid to fly ash ratio of 0.35, water replacement of 10% and 30% for 8 and 16 molarity of NaOH and has resulted in
compressive strength of 36 MPa and 20 MPa respectively. Superplasticiser dosage of 2 % by weight of fly ash has given higher
strength in all cases.
Keywords: compressive strength, alkaline liquid, fly ash
Experimental investigation on circular hollow steel columns in filled with li...eSAT Journals
Abstract
Composite Circular hollow Steel tubes with and without GFRP infill for three different grades of Light weight concrete are tested for
ultimate load capacity and axial shortening , under Cyclic loading. Steel tubes are compared for different lengths, cross sections and
thickness. Specimens were tested separately after adopting Taguchi’s L9 (Latin Squares) Orthogonal array in order to save the initial
experimental cost on number of specimens and experimental duration. Analysis was carried out using ANN (Artificial Neural
Network) technique with the assistance of Mini Tab- a statistical soft tool. Comparison for predicted, experimental & ANN output is
obtained from linear regression plots. From this research study, it can be concluded that *Cross sectional area of steel tube has most
significant effect on ultimate load carrying capacity, *as length of steel tube increased- load carrying capacity decreased & *ANN
modeling predicted acceptable results. Thus ANN tool can be utilized for predicting ultimate load carrying capacity for composite
columns.
Keywords: Light weight concrete, GFRP, Artificial Neural Network, Linear Regression, Back propagation, orthogonal
Array, Latin Squares
Experimental behavior of circular hsscfrc filled steel tubular columns under ...eSAT Journals
This document summarizes an experimental study that tested circular concrete-filled steel tube columns with varying parameters. 45 specimens were tested with different fiber percentages (0-2%), tube diameter-to-wall-thickness ratios (D/t from 15-25), and length-to-diameter (L/d) ratios (from 2.97-7.04). The results found that columns filled with fiber-reinforced concrete exhibited higher stiffness, equal ductility, and enhanced energy absorption compared to those filled with plain concrete. The load carrying capacity increased with fiber content up to 1.5% but not at 2.0%. The analytical predictions of failure load closely matched the experimental values.
Evaluation of punching shear in flat slabseSAT Journals
Abstract
Flat-slab construction has been widely used in construction today because of many advantages that it offers. The basic philosophy in
the design of flat slab is to consider only gravity forces; this method ignores the effect of punching shear due to unbalanced moments
at the slab column junction which is critical. An attempt has been made to generate generalized design sheets which accounts both
punching shear due to gravity loads and unbalanced moments for cases (a) interior column; (b) edge column (bending perpendicular
to shorter edge); (c) edge column (bending parallel to shorter edge); (d) corner column. These design sheets are prepared as per
codal provisions of IS 456-2000. These design sheets will be helpful in calculating the shear reinforcement to be provided at the
critical section which is ignored in many design offices. Apart from its usefulness in evaluating punching shear and the necessary
shear reinforcement, the design sheets developed will enable the designer to fix the depth of flat slab during the initial phase of the
design.
Keywords: Flat slabs, punching shear, unbalanced moment.
Evaluation of performance of intake tower dam for recent earthquake in indiaeSAT Journals
Abstract
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Study of different work materials effect on surface roughness in electrochemical machining process
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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STUDY OF DIFFERENT WORK MATERIALS EFFECT ON SURFACE
ROUGHNESS IN ELECTROCHEMICAL MACHINING PROCESS
Ramandeep Singh1
, Nikhil Gandotra2
, Ayyappan Solaiyappan3
1
Assistant Professor, Mechanical Department, DAV University, Jalandhar Punjab, India
2
M.tech student, Mechanical Department, DAV University, Jalandhar, Punjab, India
3
Assistant Professor, Mechanical Department, GEC, Salem, Tamilnadu, India
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.
--------------------------------------------------------------------***-----------------------------------------------------------------
1. INTRODUCTION
Electrochemical machining is a controlled atomic
dissolution of work material in which material is removed
from the work piece, not in a conventional manner, but by
the combine action of two direct forms of energies i.e.
electrical and chemical. ECM process relies on the principle
of electrolysis [3]. In electrolysis, two electrodes immersed
into a liquid solution also called electrolytic solution, in
order to deplete metal from anode and plated on cathode,
when the electric current is passed between them [2].
Though, the principle of electrolysis was in use for a long
time in a process called electroplating. But with certain
modifications, ECM is often characterized as “reverse
electroplating”, with difference of no deposition of work
material on cathode.
In today’s manufacturing era, machining quality relies on
surface finish of the machined work piece to a great extent.
ECM contributed a lot to achieve good surface finish while
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.
Various investigations have been carried out for improving
the surface roughness process characteristic of ECM process
by numerous researchers. Neto, J., et al. [1] took material
removal rate (MRR), surface roughness (SR) and over-cut as
response parameter for studying process variables in
electrochemical machining (ECM) of Valve-Steel. Surface
roughness decreases with increase in tool feed rate.
Ganesan, G., et al. [5] used non-dominated sorting genetic
algorithm-II (NSGA-II) to optimize ECM process.
Production rate was increased considerably by reducing
machining time Chakradhar, D., and Gopal, A., [4] found
tool feed rate as most influencing machining parameter by
performing ANOVA in investigation and optimization of
EN-31 steel, using grey relation analysis. Acharya, B.R., et
al. [6] adopted Response Surface Methodology to
investigate the effect of four machining parameters i.e.
electric current, voltage, electrolyte flow rate and inter-
electrode gap on MRR and SR. Surface roughness was
influenced greatly by current. Goswami, R., et al. [8]
reported the ECM of Mild Steel and Aluminium by using
Taguchi approach to analyze and predict optimal process
input characteristics for surface roughness and material
removal rate. For both materials, current was most
significant machining parameter for SR. Bisht, B., et al. [7]
used mild steel and aluminium as work material in ECM
process to optimize the machining performance. It was
concluded that aluminium alloy had good surface finish as
compared to mild steel. Das, M.K., et al. [9] applied
Artificial Bee Colony Algorithm for investigating
electrochemical machining of EN31 steel to optimize MRR
and SR. Scanning electron microscopy (SEM) images were
used to study surface characteristics. Surface roughness was
greatly influenced by electrolyte concentration.
Sathiyamoorthy, V., and Sekar, T., [11] used NaCl aqueous
solution in electrochemical machining of die steel and three
electrolyte jet patterns namely straight jet in circular,
inclined jet in circular and straight jet in spiral to analyze the
influence of electrolyte distribution on material removal rate
(MRR) and surface roughness (SR). Straight jet in spiral
pattern performed significantly in improving the
2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 506
performance of ECM. Habib, S.S., [10] used Taguchi
approach for optimization of ECM response characteristics
viz. MRR and SR by taking voltage, tool feed rate,
electrolyte concentration and current as machining
parameters. Voltage influence MRR and current influence
SR significantly. Rao, S.R., and Padmanabhan, G., [12]
done electrochemical machining process investigation by
using utility based taguchi method. Voltage, electrolyte
concentration, electrode feed rate and percentage of
reinforcement were machining parameters influencing
MRR, SR and ROC. From ANOVA, tool feed rate was most
significant machining parameter.
In the past, various researchers have attempted to study and
optimize ECM process by taking process input parameters
such as electric current, voltage, tool feed rate, electrolyte
concentration, electrolyte flow rate, inter-electrode gap etc.
and analysing their effect on response parameters viz.
material removal rate, surface roughness, radial overcut etc.,
which decide the cutting performance. A very rare work has
been done by taking work material as input parameter for
experimental study of ECM, as performance of process also
be influenced by type of work material due to its chemical
and electrical characteristics. Inspite of other important input
parameters, work material is one of the important parameter,
which affects SR. As ECM is an atomic dissolution of work
material involving chemical reactions during machining, so
chemical characteristics of work material do affect the
response parameters.
In the current research work, an effort has been made to
study the effect of input parameters on Percentage
Improvement in Ra (% ∆Ra) by selecting work material as an
input parameter along with voltage and inter-electrode gap
as another two parameters and optimize these input
parameters to improve % ∆Ra, using hexagonal shaped
copper electrode and Taguchi method. Three different
materials i.e. Mild Steel, Brass and Aluminium are taken for
experiments which are widely used in industries.
2. EXPERIMENTAL DETAILS
2.1 Experimental Set-Up
Electrochemical machining apparatus of Metatech-Industry,
Pune was used for conducting experiments as shown in
figure-1. The ECM apparatus comprises of machining unit,
control panel, electrolyte circulation tank. Machining unit is
a tough structure, accompanied with many precise
components which help in machining. It comprises of a job
holding vice and stepper motor-electrolyte supply
arrangement where tool is fixed, which helps in the
movement of tool and electrolyte flow. Control panel act as
input device which can vary the parameters like current,
voltage and feed rate. Control panel supplies power to the
machining unit. Its main function is to run and control the
machining process. The electrolyte circulation tank is fitted
with pump which supplies the electrolyte to machining unit;
a pressure gauge for determining the electrolyte pressure and
a flow control valve for deciding the amount of flow.
Fig-1: ECM Set-up
CONTROL PANEL
MACHINING UNIT
ELECTROLYTE CIRCULATION TANK
3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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2.2 Selection of Work-Piece Material
In the present research work, three different work materials
were chosen for experiments. The materials used were Mild
Steel, Brass and Aluminium. These are the commonly used
materials in industries for the fabrication of different
components and having very wide applications. Work-
pieces, equal number of each material, circular in shape
were taken for experiments having dimension of 30mm in
diameter and 20mm in thickness, as shown in figure-2.
Each work-piece was fabricated with the help of turning
operation. The chemical composition of work-piece sample
of mild steel, brass and aluminium used for present
investigation is as in table-1(a), 1(b) and 1(c).
Table-1(a): Chemical Composition of Mild Steel Work-piece
Element C Si Mn P S
Weight % 0.28 0.270 0.587 0.0285 0.0210
Table-1(b): Chemical Composition of Brass Work-piece
Element Cu Zn PB Sn Mn Fe Ni Si Al Sb
Weight % 56.1 39.3 3.23 0.37 0.03 0.29 0.28 0.03 0.10 0.01
Table-1(c): Chemical Composition of Aluminium Work-piece
Element Al Si Fe Cu Mn Mg Zn Cr Ti
Weight % 98.3 0.494 0.432 0.039 0.058 0.464 0.053 0.009 0.015
.
Fig-2: Pool of Work-pieces; extreme left- Mild steel, middle- Brass and extreme right- Aluminium
2.3 Tool and Electrolyte
Copper as tool was chosen for present investigation as it has
very high thermal and electrical conductivity. The
machining area of tool is hexagonal in shape; with head of
3mm thickness and 2 mm hole at Centre of hexagonal
shaped end of rod for the flow of electrolyte during
machining (refer Figure-3). For my present investigation,
NaCl is used as electrolyte and mineral water to make
electrolytic solution, since NaCl is a non-passive electrolyte
and do not affect the work-piece surface. Electrolyte
concentration has been kept constant throughout at 150g of
NaCl to 1 liter of mineral water. The various process
variables and their limits are specified as in table-2.
Fig-3: Machining area of copper tool
MILD STEEL BRASS ALUMINIUM
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Table-2: Process Variables and their Limits
V.NO VARIABLES UNIT LIMITS
1 voltage V 10-18
2 current A 0-280
3 Power supply Nil DC-Continuous
4 Work-Piece Material Nil Mild Steel, Brass and Aluminium
5 Tool Material Nil Copper
6 Tool-Electrode Condition Nil Non-Rotating
7 No. of Holes in Tool Nil 1
8 Tool Feed Rate mm/min 0.1
9 Inter-Electrode Gap mm 0.2-0.6
10 Electrolyte Type Nil NaCl aqua solution
11 Electrolyte Concentration g/L 150
12 Electrolyte Flow Rate L/min 9
13 Electrolyte Temperature 0
C 28
14 Electrolyte Pressure Kg/cm2
27
15 Machining Time Min 10
3. SCHEME OF EXPERIMENT
For the present experimental work, Taguchi L9 orthogonal
array having eight degree of freedom was used. From eight
degree of freedom, six degree of freedom was assigned to
three parameters; each parameter has two degree of freedom
and two degree of freedom was assigned to the error.
According to Taguchi’s methodology, the total DOF
required for the experiment must be less than or equal to
selected OA. Nine experiments were conducted according to
selected L9 OA. Three process parameters viz. work-piece
material, voltage and inter-electrode gap (IEG) were taken
as machining parameters. The degree of influence of the
machining parameters in ECM was determined by taking,
three factors, each at three levels, with equal spacing of the
cutting parameters, as shown in Table-3. The different levels
of machining parameters were allocated in standard L9 OA
by means of linear graphs is given in Table-4.
Table-3: Machining Parameters and their Stages
MACHINING PARAMETER REPRESENTATION UNIT
STAGES
STAGE-1 STAGE-2 STAGE-3
Work-Piece Material W -
Mild Steel
(M)
Brass
(B)
Aluminium
(A)
Voltage V Volts 10 14 18
Inter-Electrode Gap G mm 0.2 0.4 0.6
Table-4: Assignment of Parameters in L9 Orthogonal Array with Response
EXP
NO.
ORDER
OF RUN
MACHINING
PARAMETERS TRIAL
CONDITIONS
RESPONSE %∆Ra
(RAW DATA)
SNR (db)
W V G R1 R2 R3
1 2 3
1 1 1 (M) 1 (10) 1 (0.2) 22.04 28.01 25.03 27.84
2 4 1 (M) 2 (14) 2 (0.4) 37.50 32.54 35.02 30.84
3 7 1 (M) 3 (18) 3 (0.6) 54.04 66.84 60.44 35.53
4 2 2 (B) 1 (10) 2 (0.4) 47.29 59.9 53.60 34.46
5 5 2 (B) 2 (14) 3 (0.6) 62.43 67.43 64.93 36.24
6 8 2 (B) 3 (18) 1 (0.2) 67.49 62.18 64.84 36.22
7 3 3 (A) 1 (10) 3 (0.6) 70.31 62.94 66.63 36.45
8 6 3 (A) 2 (14) 1 (0.2) 29.47 78.75 54.11 32.59
9 9 3 (A) 3 (18) 2 (0.4) 68.15 73.32 70.74 36.98
TOTAL 458.72 531.91 495.32
R1, R2, R3 represents response value for three experimental runs. The 1’s, 2’s, and 3’s represent stages 1, 2,
and 3 of the machining parameters. T Ra =Overall mean of ΔRa = 55.04
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4. RESULTS AND ANALYSIS
From experimental data, the mean values of response
parameter and Signal-to-Noise Ratio (dB) for each
machining parameter at level one, level two and level three
(L1, L2, L3) are calculated as per in table-5. The main
effects of machining parameters both for raw data and SNR
data are plotted in figure-4 (a, b and c). The significance and
optimal conditions of machining parameters for mean
response parameter are recognized by analyzing response
curves and the ANOVA Tables.
Table-5: Mean values & main effects of Percentage improvement in surface roughness (∆Ra)
Machining
Parameter
Stage Work-piece Material Voltage IEG
Type of Data
Levels
Raw
Data
SNR
(dB)
Raw
Data
SNR
(dB)
Raw
Data
SNR (dB)
Mean Values
(SR)
S1 40.16 31.41 48.42 32.92 47.99 32.22
S2 61.12 35.64 51.35 33.22 53.12 34.10
S3 63.82 35.34 65.34 36.24 63.10 36.07
Main Effects
(SR)
S2-S1 20.96 4.24 2.94 0.31 5.13 1.88
S3-S2 2.71 -0.30 13.98 3.02 10.88 1.98
Difference {( S3-S2)-( S2-
S1)}
-18.26 -4.54 11.05 2.72 5.76 0.10
S1, S2 & S3 represent stages 1, 2, & 3 respectively of parameters. S2-S1 is the mean main effect when the
corresponding parameter varies from Stage 1 to Stage 2. S3-S2 is the main effect when the corresponding
parameter varies from Stage 2 to Stage 3.
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Fig- 4(a) Influence of Work-piece Material; (b) Effect of Voltage and (c) Effect of IEG on S/N ratio and percentage improvement
in Surface Roughness
The effect of Work-piece Material on Percentage
Improvement in Surface Roughness and Signal-to-Noise
Ratio is clearly visible in Figure-4(a). Figure shows that the
percentage improvement in Ra is highest when brass is used
as work-piece and lowest in case of mild steel. Percentage
improvement in Ra is almost same in case of brass and
aluminium. This is due to different characteristics of
different materials like Crystallographic irregularities, such
as dislocation. An uneven distribution of current density is
produced due to different composition of alloy, which leaves
the microscopic peaks and valleys that form poor surface
finish. More fine grained as well as homogenous structures
produce a better surface quality. It also depends on the
machining conditions and electrolyte selected for
machining.
Figure-4(b) represents the influence of voltage on Signal-to-
noise ratio (SNR) and Percentage improvement in Ra.
Percentage Improvement in Ra increases directly as the
voltage is changed from 10V to 18V. Highest percentage
improvement in Ra is obtained at 18V. The lowest
percentage improvement in Ra is observed when 10V
voltage is used. There is less increase in surface finish when
voltage changes from 10V to 14V as when voltage changes
from 14V to 18V. This is due to reason that surface finish
increases with increase in current and current increases
when voltage is increased. When the applied voltage is low,
current in the IEG is lower which leads to uneven
dissolution of material resulting higher surface roughness
and vice-versa.
One more parameter that affects the percentage
improvement in Ra is Inter-Electrode Gap. Figure-4(c)
shows the variation of percentage improvement in Ra with
respect to various values of IEG. The Figure show that the
percentage improvement in Ra increases directly and linearly
when IEG changes from 0.2mm to 0.6mm. Lower value of
percentage improvement in Ra is observed at 0.2mm IEG
and highest value of percentage improvement in Ra is
observed at 0.6mm IEG. This is due to reason that the
electrolyte used was concentrated NaCl. Salts crystallize out
of the solution at higher concentrations which increase the
MR but decrease the surface finish. So, surface finish will be
better at high IEG and high voltage using concentrated
electrolyte.
Analysis of Variance (ANOVA) was executed on
experimental data to find significance of the machining
parameters towards the Percentage Improvement in Surface
Roughness. The Pooled ANOVA of raw data and the SNR
data for percentage improvement in Ra are given in Tables-6
and 7.
Table-6: Pooled ANOVA of Raw Data for Percentage Improvement in Surface Roughness
SOURCE SS DOF V F- RATIO P%
Work-piece Material 33.50 2 16.75 32.85 43.45
Voltage 20.30 2 10.15 19.91 26.33
IEG 22.28 2 11.14 21.85 28.90
Error 1.02 20 0.51 1.32
Total (T) 77.09 26 -- 100
Significance at 95% confidence level, Fcritical =3.55
SS- Sum of Squares, DOF- Degree of Freedom, V- Variance
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Table-7: Pooled ANOVA of S/N Ratio Data for Percentage Improvement in Surface Roughness
SOURCE SS DOF V F- RATIO P%
Work-piece Material 3019.30 2 1509.65 20.08 41.95
Voltage 1471.53 2 735.77 9.79 20.45
IEG 1202.88 2 601.44 8.00 16.71
Error 1503.55 2 75.18 20.89
Total (T) 7197.27 8 -- 100
Significance at 95% confidence level, Fcritical =3.55
SS- Sum of Squares, DOF- Degree of Freedom, V- Variance
From ANOVA tables, the mean and variation in percentage
improvement in surface roughness values were considerably
affected by work-piece material, voltage and IEG. The
percentage influence of work-piece material is highest
(43.45%) for improvement in surface roughness followed by
the IEG (28.90%), and voltage (26.33%). Percentage
improvement in surface roughness is considered as “higher
the better” type of quality characteristic. Therefore, higher
values of machining parameters are considered to be
optimal.
The S/N ratio analysis (refer Table-5 and Figure-4) suggests
that Second level of material of work-piece (Brass) and
Third level of voltage (18V) and IEG (0.6mm) are the
optimum levels of parameters for maximum percentage
improvement in Ra (i.e. Least Surface Roughness).
5. ASSESSMENT OF OPTIMAL VALUE OF
RESPONSE PARAMETER
The effect of the significant machining parameters helps in
assessment of optimal value of response parameter within
confidence interval. The confirmation experimentations give
the mean value of response parameter, which must lie within
the 95% confidence interval of confirmation experiment and
mean value of quality characteristic obtained from the
confirmation experiments may or may not lie within 95%
confidence interval of population.
The optimal value of ∆Ra is estimated as:
∆Ra = TGVW 2332 (1)
T̅ = overall mean of response = 55.04 (Table-4)
2W = Mean value of Ra at the 2nd level of Work-piece
Material =
61.12 (Table-5)
3V = Mean value of Ra at the 3rd level of Voltage = 65.34
(Table-5)
3G = Mean value of Ra at the 3rd level of IEG = 63.10
(Table-5)
Substituting these values in equation 1, ∆Ra = 79.48
The confidence interval of confirmation experiments (CICE)
and of population (CIPOP) is calculated by using the
following equations:
R
1
n
1
V)f(1,FCI
eff
eeαCE
(2)
eff
eeα
POP
n
V)f(1,F
CI
(3)
Where,
Fα (1, fe) = The F-ratio at the confidence level of (1-α)
against DOF 1 and error degree of freedom fe = 4.35
(Tabulated F value)
fe = Error DOF = 20 (Table-6)
N = Total number of outcome = 27 (conduct = 9, replication
= 3)
R = Sample size for confirmation experiments = 3
Ve = Variance Error = 0.51 (Table-6)
neff =
N
1+[DOF associated in the predicted mean response ]
= 3.87
So, CICE = ± 1.146
And CIPOP = ± 0.758
The 95% confidence interval of predicted optimal range is:
Mean Ra – CICE < ∆Ra > Mean Ra + CICE
78.344 < ∆Ra > 80.626
The 95% confidence interval of the predicted mean is:
Mean Ra – CIPOP < ∆Ra > Mean Ra + CIPOP
78.722 < ∆Ra > 80.238
6. CONFIRMATION EXPERIMENT
Three confirmation experiments were performed, to
authenticate the results acquired, for response parameter i.e.
percentage improvement in Ra at the optimal levels of
Work-piece Material at Second level (W2), Voltage at level
Three (V3), and IEG which is also at Third level (G3). The
confirmation result is given in table-8. The experimental
values of percentage improvement in Surface Roughness
attained through the confirmation experiments were within
95% of confidence intervals of respective response
characteristic.
8. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 512
Table-8: Outcome of Confirmation Experiments within Confidence Intervals
Response
Parameter
Optimal
Machining
Parameters
Predicted
Optimum
Value
95% Confidence Interval Authentic Value
(Avg. of
Confirmation
Exp.)
%age Improvement
in Ra
W2V3G3 79.48 CICE:78.344<∆Ra >80.626
CIPOP:78.722<∆Ra >80.238
79.243
CICE – Confidence interval for the mean of the confirmation experiments
CIPOP – Confidence interval for the mean of the population
7. CONCLUSION
The important conclusions from the present experimental
study are summarized below:
Effect of machining parameters i.e. work-piece
material, voltage and inter-electrode gap (IEG) on
percentage improvement in SR was prominent.
Work-piece material was established as most
significant factor affecting percentage improvement
in SR followed by Inter-electrode gap and Voltage.
Highest value of Percentage Improvement was
observed in case of brass as work-piece and lowest in
case of mild steel.
Percentage Improvement in Ra was increased linearly
in case of IEG. Highest Percentage Improvement in
Ra was observed at 0.6mm and lowest was observed
at 0.2mm.
Percentage improvement in Ra was increased
gradually as voltage was change from 10V to 18V.
Percentage Improvement in Ra was highest at 18V
and lowest at 10V.
The optimal set of parameters were second level of
work material (Brass), third level of voltage (18V)
and third level of IEG (0.6mm).
Overall, it was found that characteristics of work
material influence the Improvement in Surface
Roughness as well as other operating conditions of
ECM process.
ACKNOWLEDGEMENTS
The authors appreciatively acknowledge the Technical
Education Quality Improvement Programme (TEQIP)
scheme of World Bank for funding electrochemical
machining apparatus used for experiments at Mechanical
Engineering Department of Govt. College of Engineering,
Salem, Tamilnadu, India.
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9. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 07 | July-2015, Available @ http://www.ijret.org 513
BIOGRAPHIES
Ramandeep Singh I received
my B.tech degree from
Regional Engineering College,
Jalandhar, Punjab, India, in
1998, the M.tech degree from
Regional Engineering College,
Kurukshetra, India, in 2000 and
is pursuing my doctorate studies
from PEC University of
Technology, Chandigarh, India.
I am having more than fourteen
years of experience in industry
and teaching of graduate and postgraduate students. I am
having more than 30 research papers to my credit. Also
guided three postgraduate students.
Nikhil Gandotra received his
degree of B.tech in Mechanical
Engineering from DAVInstitute
of Engineering and Technology,
Jalandhar, Punjab, India in June
2012. He is pursuing M.tech in
Mechanical Engineering with
specialization in Production
from DAV University,
Jalandhar, Punjab, India.He is having one yearexperience in
teaching of diploma students. His areas of interest include
Non-conventional machining, Production& Industrial
engineering, Virtual manufacturing, Quality control and
improvement.