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
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
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.
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.
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.
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 the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of 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.
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
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.
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.
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.
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 the Process Parameters of Wire Cut EDM - A ReviewIJSRD
The objective of this paper is to study the effect of different process parameter of wire electrical discharge machine (WEDM) process on the performance measures such as material removal rate (MRR), surface roughness, dimensional accuracy and kerf width. It is necessary to evaluate the factors that affect the productivity and efficiency of WEDM process. It will directly contribute to increase cutting speed and dimensional accuracy.
Optimization of 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.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
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.
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.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
This document describes a framework developed using Taguchi methods to optimize two quality characteristics, surface roughness and angular accuracy, in wire electrical discharge machining (W-EDM) operations. An experiment was conducted using an L9 orthogonal array to investigate the effects of four controllable factors (pulse on time, feed rate, voltage, and wire tension), each at three levels, on the two response variables. The optimal settings identified were able to improve both surface roughness and angular accuracy, as confirmed through additional validation experiments. This research established a systematic approach for obtaining a single optimal parameter setting to maximize multiple quality characteristics simultaneously in machining applications.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
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.
Optimization of Cutting Rate for EN 1010 Low Alloy Steel on WEDM Using Respon...IJAEMSJORNAL
The document describes an experiment to optimize cutting rate (CR) when machining EN 1010 low alloy steel using wire electric discharge machining (WEDM). Central composite design was used to plan experiments varying pulse on time, pulse off time, peak current, and servo voltage. 21 experiments were conducted and the average CR was measured for each. Response surface methodology was applied to develop a model relating the process parameters to CR. Analysis of variance showed the quadratic model adequately described the relationship with an R2 of 0.970641. An empirical equation was derived to predict optimal CR based on settings of the four process parameters.
This document analyzes the effect of different wire electrodes on the material removal rate (MRR) of an MS workpiece using wire electrical discharge machining (WEDM). Experiments were conducted using copper, brass, and zinc-coated brass wire electrodes at various levels of current and pulse duration. The results showed that MRR was highest with copper wire and decreased with brass and zinc-coated brass wires. MRR also decreased with increasing current but increased with longer pulse duration. Statistical analysis through ANOVA confirmed that the wire material and pulse duration significantly affected the MRR while current had a lesser effect.
Optimization of 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.
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
Investigation on process response and parameters in wire electrical discharge...IAEME Publication
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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.
Effect Of Wire Edm Process Parameters On Surface Roughness Of Aisi-4140 (Carb...dbpublications
WEDM is used for cutting intricate or complicated shapes which are not possible with conventional machining methods. Wire cut EDM is a cutting process used widely where conventional machining processes are not useful. A metal wire with a Dielectric medium travels through a path and perform machining procedure .The main objective of the present work is to investigate the effects of various WEDM process parameters on the machining quality and to obtain the optimal sets of process parameters like Pulse-ON time, Pulse-OFF time, current, wire feed are studied by conducting an experiment. Taguchi Method is to design the experiment. L16 orthogonal array is used to conduct the experiment. An AISI-4140 (carbon steel) is used as a work piece material in the form of square bar. The surface roughness (SR) is selected as response variable.
Investigation on process response and parameters in wire electricaliaemedu
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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.
Face detection for video summary using enhancement based fusion strategyeSAT 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
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
Hybrid fingerprint matching algorithm for high accuracy and reliabilityeSAT 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.
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
International Journal of Engineering Research and Development (IJERD)IJERD Editor
call for paper 2012, hard copy of journal, research paper publishing, where to publish research paper,
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
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.
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.
Optimization of edm process parameters using taguchi method a revieweSAT Journals
Abstract
Electrical discharge machining is assessed on the basis of Material Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR). Process parameters that mostly affected the EDM Process are Pulse on Time, Pulse off Time, Discharge Current, Arc Gap and Duty Cycle. This paper reviews research for the optimization and improvement of various performance parameters measured in the experimentation on EDM by using Taguchi technique. In the study the main objectives of optimization is to minimize the tool wear rate (TWR) and surface roughness, and to maximize the material removal rate (MRR).Taguchi Method is widely used in the industry to optimize and improve various performance parameters associated with different machining processes. This paper also deals with the review of some of the work reported with the use of Taguchi method in last two decades.
Keywords: - EDM, Wire EDM, MRR, RWR, TWR, SR, Taguchi Technique
This document summarizes a research study that investigated near-dry electrical discharge machining (EDM) to optimize material removal rate (MRR) and surface finish. The study used a Taguchi L9 orthogonal array design of experiments to examine the effects of discharge current, pulse on time, gap voltage, and pulse off time on MRR and surface roughness. Response surface methodology was employed to optimize both responses simultaneously. The experimental results found that near-dry EDM achieved a better surface finish compared to wet EDM due to more stable machining at lower discharge energies. MRR and surface roughness were modeled as functions of the process parameters. The models showed the parameters and their interactions significantly affected MRR.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
This document describes a framework developed using Taguchi methods to optimize two quality characteristics, surface roughness and angular accuracy, in wire electrical discharge machining (W-EDM) operations. An experiment was conducted using an L9 orthogonal array to investigate the effects of four controllable factors (pulse on time, feed rate, voltage, and wire tension), each at three levels, on the two response variables. The optimal settings identified were able to improve both surface roughness and angular accuracy, as confirmed through additional validation experiments. This research established a systematic approach for obtaining a single optimal parameter setting to maximize multiple quality characteristics simultaneously in machining applications.
Multiple Optimization of Wire EDM Machining Parameters Using Grey Based Taguc...IJMER
Wire EDM is a non conventional machining process, which is used when the precision is prime importance. Multiple optimization (Grey based Taguchi) technique is used to find out the optimum machining setup for input parameter. This paper investigate the optimal set of process parameter such as Ton, Toff, Wp, Wf in wire EDM machining process to find out the variation in two output parameter such as material removal rate (MRR), and surface roughness (Ra) on material high chromium high carbon steel (HCHCr) using wire Brass/super alloy (coated).Experimentation was conducted on orthogonal array L-9 based on DOE. Analysis of experiment has been carried out using GRA. All the experimental data are fed into Minitab software, through which various tables, graphs & optimum values are obtained. The experimental result reveals that the optimum setting of input parameters significantly improves Wire EDM process.
Wire EDM Parameters for Surface Roughness in Straight Gear Manufacturing: An ...Dr. Amarjeet Singh
The gears are an essential component of any system. A gear is a spinning circular machine part with cut teeth, or inserted teeth (called cogs) in the case of a cogwheel or gearwheel, which mesh with another toothed part to convey torque. A gear is sometimes referred as a cog colloquially. Geared devices can adjust a power source's speed, torque, and direction. To eliminate backlash, high precision is required while making gears. Wire cut EDM is a high-precision machining technology that may manufacture high-precision straight gear. The goal of this research is to use the WEDM Process on an EMS 45 to determine the surface roughness of the workpiece and to optimise the influence of current and wire speed on the surface roughness of the straight gear. Wire cut machining parameters employed were 4, 6, and 8 amperes of current and 9, 11, and 13 mm/min of wire speed. Wire has a diameter of 0.25 mm, and the cutting material is brass. It has been demonstrated that as current and wire speed increase, surface roughness decreases, and vice versa. As a result, reduced machine settings can be used to generate a smoother and better workpiece surface.
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.
Optimization of Cutting Rate for EN 1010 Low Alloy Steel on WEDM Using Respon...IJAEMSJORNAL
The document describes an experiment to optimize cutting rate (CR) when machining EN 1010 low alloy steel using wire electric discharge machining (WEDM). Central composite design was used to plan experiments varying pulse on time, pulse off time, peak current, and servo voltage. 21 experiments were conducted and the average CR was measured for each. Response surface methodology was applied to develop a model relating the process parameters to CR. Analysis of variance showed the quadratic model adequately described the relationship with an R2 of 0.970641. An empirical equation was derived to predict optimal CR based on settings of the four process parameters.
This document analyzes the effect of different wire electrodes on the material removal rate (MRR) of an MS workpiece using wire electrical discharge machining (WEDM). Experiments were conducted using copper, brass, and zinc-coated brass wire electrodes at various levels of current and pulse duration. The results showed that MRR was highest with copper wire and decreased with brass and zinc-coated brass wires. MRR also decreased with increasing current but increased with longer pulse duration. Statistical analysis through ANOVA confirmed that the wire material and pulse duration significantly affected the MRR while current had a lesser effect.
Optimization of 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.
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
Investigation on process response and parameters in wire electrical discharge...IAEME Publication
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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.
Effect Of Wire Edm Process Parameters On Surface Roughness Of Aisi-4140 (Carb...dbpublications
WEDM is used for cutting intricate or complicated shapes which are not possible with conventional machining methods. Wire cut EDM is a cutting process used widely where conventional machining processes are not useful. A metal wire with a Dielectric medium travels through a path and perform machining procedure .The main objective of the present work is to investigate the effects of various WEDM process parameters on the machining quality and to obtain the optimal sets of process parameters like Pulse-ON time, Pulse-OFF time, current, wire feed are studied by conducting an experiment. Taguchi Method is to design the experiment. L16 orthogonal array is used to conduct the experiment. An AISI-4140 (carbon steel) is used as a work piece material in the form of square bar. The surface roughness (SR) is selected as response variable.
Investigation on process response and parameters in wire electricaliaemedu
This document summarizes a study that investigated the effects of process parameters on performance measures during wire electrical discharge machining (WEDM) of Inconel 625. The study considered the effects of pulse-on time, pulse-off time, upper flush, lower flush, wire feed, and wire tension on cutting width, electrode wear, and hardness. Experiments were conducted using an orthogonal array design and relationships between the control factors and responses were established through regression analysis. The results showed good agreement between experimental and predicted values of the performance measures.
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.
Face detection for video summary using enhancement based fusion strategyeSAT 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
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
Hybrid fingerprint matching algorithm for high accuracy and reliabilityeSAT 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.
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
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.
Exploring the preferred temperature on occupants thermal comfort in the humid...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
Design and implementation of a fuzzy based tsunami warning systemeSAT Publishing House
This document describes the design and implementation of a fuzzy-based tsunami warning system. It begins with an introduction to tsunamis and their causes. A fuzzy logic system is then developed using Mamdani's fuzzy inference method in MATLAB. Four parameters are used as inputs - earthquake magnitude, volcanic eruption index, landslide, and deep ocean wave height. Membership functions are defined for the inputs and single output, "alert type." Fuzzy rules are generated based on historical tsunami data. The system outputs one of three linguistic alert levels: rare tsunami, advisory tsunami, or warning. The fuzzy logic approach allows the system to model the vagueness of tsunami prediction based on multiple contributing factors.
Factors affecting def and asr in the concrete dam at vrané nad vltavoueSAT Publishing House
1) The document examines factors affecting delayed ettringite formation (DEF) and alkali-silica reaction (ASR) in concrete from a dam in Vrané nad Vltavou, Czech Republic.
2) Samples were taken from 8 locations and tested for residual expansion, then analyzed using microscopy techniques. The sample with the highest residual expansion and microcracking was periodically exposed to water.
3) DEF was found to be the primary degradation mechanism. The sample most affected was located 1 meter above the water line and contained aggregates of acidic volcanic rock that are susceptible to DEF when periodically exposed to water.
Soft subgrade stabilization with quarry dust an industrial wasteeSAT Publishing House
This document summarizes a study on stabilizing soft subgrade soil using quarry dust, an industrial waste product. Laboratory tests were conducted on soil mixed with various percentages of quarry dust. Tests found that adding up to 40% quarry dust decreased the soil's liquid limit and plasticity index while increasing the maximum dry density and California Bearing Ratio (CBR), indicating increased strength. Specifically, soil mixed with 40% quarry dust saw a 5.88% increase in maximum dry density and a 228% increase in CBR compared to the unmodified soil. The study thus demonstrates the potential of using quarry dust to improve soft subgrade soil for supporting flexible pavements in a more economical way compared to removing and replacing
Performance of blended corrosion inhibitors for reinforced concreteeSAT Publishing House
This document discusses the performance of blended corrosion inhibitors for reinforced concrete. It summarizes the results of experiments conducted to evaluate the effect of a blend of calcium nitrite and calcium hypophosphite corrosion inhibitors on the physical properties and corrosion resistance of cement and concrete. The experiments found that the corrosion inhibitor blend did not adversely affect the setting time, pH, or compressive strength of cement or concrete. Electrochemical tests also showed that the corrosion inhibitor blend reduced the corrosion current density, demonstrating its potential to control corrosion initiation and propagation in reinforced concrete.
This document discusses computational fluid dynamics (CFD) analysis of flow over an airfoil integrated with spikes at supersonic speeds. It presents the results of CFD simulations using ANSYS Fluent software to analyze the effect of adding either a sharp spike or hemispherical spike to a NACA 651-412 airfoil at Mach numbers over 1. The study found that the addition of spikes modifies the flow field over the airfoil and changes the aerodynamic lift and drag coefficients. Spikes help reduce problems like higher heating and separation that occur during supersonic flight.
This document describes a proposed mobile application that would allow users to report hazardous objects to the appropriate authorities. The application would use the device's GPS to tag photos, videos, or audio recordings with location data. This media would then be uploaded to a central server and displayed on a map for relevant government departments to view. The goal is to create a single platform for citizens to report issues and hazards, so authorities can better understand problems and locations that require attention. Key features would include media capture, GPS integration, and displaying reported incidents on a map via the Google Maps API.
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
Performance investigation of electricial power supply to owerri for higher pr...eSAT Publishing House
This document investigates the performance of electrical power supply to Owerri, Nigeria by analyzing data collected from the Enugu Electricity Distribution Company and customers. It finds that major issues include inadequate available megawatts, obsolete equipment, network overloads, poor funding, and lack of maintenance. On average, power is supplied for only 29-46% of the time needed. While privatization aims to address challenges, issues remain like technical faults, heat losses during transmission, and supplying only 85 megawatts daily against demand. Recommendations include equipment upgrades, cooperation between government, private sectors and customers, and smart metering to ensure proper billing.
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
Surveillance and tracking of elephants using vocal spectral informationeSAT 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
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.
Effect of prism height on strength of reinforced hollow concrete block masonryeSAT 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.
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
Sdci scalable distributed cache indexing for cache consistency for mobile env...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.
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%.
Modeling and Analysis of process parameters on Surface Roughness in EDM of AI...Mohan Kumar Pradhan
Response Surface Methodology (RSM)
is used to investigate the effect of four controllable input variables
namely: discharge current, pulse duration, pulse off time and applied
voltage Surface Roughness (SR) of on Electrical Discharge Machined
surface. To study the proposed second-order polynomial model for
SR, a Central Composite Design (CCD) is used to estimation the
model coefficients of the four input factors, which are alleged to
influence the SR in Electrical Discharge Machining (EDM) process.
Experiments were conducted on AISI D2 tool steel with copper
electrode. The response is modeled using RSM on 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 SR. The model sufficiency
is very satisfactory as the Coefficient of Determination (R2) is found
to be 91.7% and adjusted R2-statistic (R2
adj) 89.6%.
Modeling and optimization of EDM Process Parameters on Machining of Inconel ...ROEVER GROUPS
This document summarizes a research paper that models and optimizes electrical discharge machining (EDM) process parameters for machining Inconel 686. The researchers conducted experiments with four controllable input parameters (spark current, pulse on time, duty cycle, voltage) using a face-centered central composite design. They analyzed the effects of the parameters on material removal rate, tool wear rate, and surface roughness using analysis of variance. Models were developed that showed the parameters significantly affected the output characteristics. The models had high R-squared values and adequate precision above 4, indicating good predictability and design adequacy.
MODELING AND OPTIMIZATION OF EDM PROCESS PARAMETERS: A REVIEWIAEME Publication
Electrical discharge machining (EDM) is one of the earliest non-traditional machining processes. EDM process is based on thermo electric energy between the work piece and an electrode. There are different input parameters which influence on the outputs such as MRR, TWR and SR.
Optimization is one of the techniques used in manufacturing sectors to arrive for the best manufacturing conditions, which is an essential need for industries towards manufacturing of quality products at lower cost.
MULTI OBJECTIVE OPTIMIZATION OF NEAR-DRY EDM PROCESS USING RESPONSE SURFACE M...IAEME Publication
The correct selection of manufacturing technique is one of the most important aspects to take into consideration in the majority of manufacturing processes and particularly in processes related to Electrical Discharge Machining (EDM). It is capable of machining geometrically complex or hard
material components, which are precise and difficult-to-machine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mold making industries, aerospace, aeronautics and nuclear industries.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
Process Parameter Optimization of WEDM for AISI M2 & AISI H13 by Anova & Anal...IJERA Editor
The document summarizes a study on optimizing process parameters for wire electrical discharge machining (WEDM) of AISI M2 and AISI H13 steel alloys. Experiments were conducted using a Taguchi L16 orthogonal array with peak current, pulse on time, pulse off time, and workpiece material as parameters. Responses measured included material removal rate, surface roughness, kerf width, and spark gap. ANOVA showed peak current and pulse on time most significantly affected responses. For AISI M2, low peak current, short pulse on and off times minimized surface roughness and kerf width while maximizing material removal rate. For AISI H13, low peak current, long pulse on time
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.
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
Optimization of EDM Process of (Cu-W) EDM Electrodes on Different ProgressionIJERA Editor
This document summarizes previous research on optimizing EDM (electrical discharge machining) processes using different compositions of Cu-W electrodes. It discusses factors like material removal rate, tool wear rate, surface roughness, and how they are affected by machining parameters like discharge current, voltage, pulse-on time, duty cycle and flushing pressure. The document reviews several past studies that investigated these relationships and optimized the EDM process for different materials. It provides figures from some of these past studies to illustrate their findings.
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.
Optimization of Surface Roughness for EN 1010 Low Alloy Steel on WEDM Using R...IJAEMSJORNAL
This document describes research into optimizing the surface roughness of EN 1010 low alloy steel using wire electrical discharge machining (WEDM). Experiments were conducted using a central composite design to investigate the effects of four process parameters (pulse on time, pulse off time, peak current, and servo voltage) on surface roughness. Analysis of variance was used to identify significant parameters and develop a mathematical model relating the parameters to surface roughness. The model achieved a good fit to the data and can be used to determine the optimal parameter settings that minimize surface roughness.
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
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.
Development of a Taguchi-based framework for optimizing two quality character...IJERA Editor
A framework based on Taguchi parameter design was developed and successfully demonstrated to optimize two
quality characteristics- surface roughness and angular accuracy in Wire Electrical Discharge Machining (WEDM)
process. An orthogonal array (OA)L9was used in the Taguchi experiment design for four controllable
factors, each with three levels. With one non-controllable factor investigated, 18 experiments were conducted in
the Taguchi-based experiment setting, compared to 3
4
(=81) parameter combination as required by a traditional
DOE setting. Conducted for the two response variables, Taguchi experiments from the case study gave the
optimal combination of pulse on time at 9µs (A1), feed rate at 35 in/min (B2), voltage at 8v (C2), and wire
tension at 165g (D3) for surface roughness optmization, and pulse on time at 13µs (A3), feed rate at 35 in/min
(B2), voltage at 8v (C2), and wire tension at 160g (D2) for angular accuracy optmization. This optimal parameter
setting combination was verified through a confirmation run that confirms the optimal quality responses of
126.1µin for surface roughness and 0.024º for angular accuracy. This research ultimately showed the dual
output variable improvement and the framework established itself as a means to solve similar problems in other
machining applications. The developed framework can serve as guidance for researchers to obtain multivariable
optimal setting in a systematic way.
Comparison of fuzzy logic and neural network for modelling surface roughness ...ijmech
Surface roughness is the main indicator of technological performances of a component for electrical discharge machining (EDM). EDM process of manganese alloyed cold-work tool steel was modelled. In this paper we used the fuzzy logic (FL) and neural network (NN) to predict the effect of machining variables (discharge current and pulse duration) on the surface roughness of manganese alloyed cold-work tool steel in order to improve and increase its range of application. The experiments are carried out on
manganese alloyed cold-work tool steel, processed with electrodes made of copper. The values of surface
roughness predicted by these models are then compared. All models show good agreement with experimental results. When compared to the NN and FL models, the NN model has shown a significant forecast improvement. The results indicate that the NN model is an effective algorithm to forecast the surface roughness in EDM.
The document presents a mathematical modeling and analysis of the influence of process parameters on material removal rate (MRR) during electrical discharge machining (EDM) of stainless steel 304. Experiments were conducted to determine the effects of peak current, pulse on time, and pulse off time on MRR. Using Taguchi methods, an optimal combination of parameters was identified to achieve maximum MRR. Analysis of variance confirmed the significant effects of the parameters on MRR. Regression analysis was then used to develop a second order full quadratic mathematical model relating MRR to the process parameters. The model was found to have acceptable accuracy in predicting response values based on its R2 and adjusted R2 values. Interaction effects between the parameters were also studied.
Trends in Wire Electrical Discharge Machining (WEDM): A ReviewIJERA Editor
This document summarizes research on trends in wire electrical discharge machining (WEDM). It reviews several studies that investigated how WEDM process parameters affect outcomes like surface roughness, cutting speed, and material removal rate. Different materials were examined, including metals, composites, and silicon. Process parameters like pulse on-time, current, wire feed rate, and dielectric fluid composition were found to influence the results. Statistical methods like Taguchi experiments and analysis of variance were commonly used to determine significant factors and optimize the process.
Similar to Study of surface roughness for discontinuous (18)
Hudhud cyclone caused extensive damage in Visakhapatnam, India in October 2014, especially to tree cover. This will likely impact the local environment in several ways: increased air pollution as trees absorb less; higher temperatures without tree canopy; increased erosion and landslides. It also created large amounts of waste from destroyed trees. Proper management of solid waste is needed to prevent disease spread. Suggested measures include restoring damaged plants, building fountains to reduce heat, mandating light-colored buildings, improving waste management, and educating public on health risks. Overall, changes are needed to water, land, and waste practices to rebuild the environment after the cyclone removed green cover.
Impact of flood disaster in a drought prone area – case study of alampur vill...eSAT Publishing House
1) In September-October 2009, unprecedented heavy rainfall and dam releases caused widespread flooding in Alampur village in Mahabub Nagar district, a historically drought-prone area.
2) The flood damaged or destroyed homes, buildings, infrastructure, crops, and documents. It displaced many residents and cut off the village.
3) The socioeconomic conditions and mud-based construction of homes in the village exacerbated the flood's impacts, making damage more severe and recovery more difficult.
The document summarizes the Hudhud cyclone that struck Visakhapatnam, India in October 2014. It describes the cyclone's formation, rapid intensification to winds of 175 km/h, and landfall near Visakhapatnam. The cyclone caused extensive damage estimated at over $1 billion and at least 109 deaths in India and Nepal. Infrastructure like buildings, bridges, and power lines were destroyed. Crops and fishing boats were also damaged. The document then discusses coping strategies and improvements needed to disaster management plans to better prepare for future cyclones.
Groundwater investigation using geophysical methods a case study of pydibhim...eSAT Publishing House
This document summarizes the results of a geophysical investigation using vertical electrical sounding (VES) methods at 13 locations around an industrial area in India. The VES data was interpreted to generate geo-electric sections and pseudo-sections showing subsurface resistivity variations. Three main layers were typically identified - a high resistivity topsoil, a weathered middle layer, and a basement rock. Pseudo-sections revealed relatively more weathered areas in the northwest and southwest. Resistivity sections helped identify zones of possible high groundwater potential based on low resistivity anomalies sandwiched between more resistive layers. The study concluded the electrical resistivity method was useful for understanding subsurface geology and identifying areas prospective for groundwater exploration.
Flood related disasters concerned to urban flooding in bangalore, indiaeSAT Publishing House
1. The document discusses urban flooding in Bangalore, India. It describes how factors like heavy rainfall, population growth, and improper land use have contributed to increased flooding in the city.
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1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 727
STUDY OF SURFACE ROUGHNESS FOR DISCONTINUOUS
ULTRASONIC VIBRATION ASSISTED ELECTRIC DISCHARGE
MACHINING USING RSM
Jujhar Singh1
, Sukhvir Singh2
, Gurpreet Singh3
1, 2, 3
Mechanical Engineering Department, Rayat-Bahra Institute of Engineering & Bio-Technology,
Kharar, Distt. Mohali, Punjab, India
jujharsingh2085@gmail.com, sukhvir.1991@gmail.com, hanspal89@gmail.com
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)
-----------------------------------------------------------------------***---------------------------------------------------------------------
1. INTRODUCTION
In today's world, there is an essential requirement of advance
materials such as high strength alloys, ceramics, fiber-
reinforced composites etc. These materials are very hard in
nature and are difficult to machine. To get rid from this
machining problem, Electric Discharge Machining (EDM)
was invented. EDM works on the principle of spark erosion,
which removes the material by eroding the work piece. The
main equipments of the Electric Discharge Machine are D.C.
supply unit, EDM circuit, servomechanism, dielectric unit etc.
There is a gap between the tool (electrode) and the work piece,
which is known as spark gap. To complete the circuit the
current is passed through the tool and the work piece through
dielectric fluid. The current tends to break the dielectric fluid
into ions, which start moving from work piece to tool. The
movement of ions and electrons between tool and work piece
occurs at such a high speed that it seems as a spark. This
transfer of ions and electrons increases the temperature, which
melts the work piece. The spark melts a small material volume
on each of the electrodes. The dielectric fluid that fills the gap
between the electrodes removes part of this material.
The circulation of dielectric fluid and the removal of
machined-debris is very difficult, especially when the hole or
the cavity becomes deep, which reduces the machining
efficiency due to poor circulation of the dielectric fluid from
working gap. This poor flushing ends up with stagnation of
dielectric and builds-up machining residues which apart from
low material removal rate (MRR) also lead to short circuits
and arcs. To improve the machining performance of EDM, a
combined method of ultrasonic vibration and Electric
Discharge Machining has been developed by some
researchers. Response-surface methodology comprises a body
of methods for exploring for optimum operating conditions
through experimental methods. Typically, this involves doing
several experiments, using the results of one experiment to
provide direction for what to do next. This next action could
be to focus the experiment around a different set of conditions,
or to collect more data in the current experimental region in
order to fit a higher-order model [1]. Shabgard et al. concluded
that the regression technique is an important tool for
representing the relation between machining characteristic and
EDM process input parameters. The results show, that the
CCD is a powerful tool for providing experimental diagrams
and statistical-mathematical models, to perform the
experiments appropriately and economically [2]. Asif and
khan used RSM to investigate the relationships and parametric
interactions between three controllable variables on the
material removal rate(MRR), electrode wear rate (EWR) and
SR in EDM milling of AISI 304 steel. Developed models can
be used to get the desired responses within the experimental
2. IJRET: International Journal of Research in Engineering and Technology
__________________________________________________________________________________________
Volume: 02 Issue: 11 | Nov-2013, Available @
range[3]. Sahoo et al. demonstrated the effect of most
influencing parameters on SR using RSM for different work
piece materials in EDM [4]. Kanagarajan et al. developed
models for the MRR and SR over the most influencing process
parameters in EDM of WC/30% Co composites. The RSM
methodology is used to identify the most influential
parameters for maximizing metal removal rate and for
minimizing the SR[5]. Shabgard and Shotorbani suggested
mathematical models for relating the MRR, TWR and
machining parameters. RSM approach is used to determine the
relationship between various process parameters and
machining criteria of FW4 welded steel[6]. Pradhan et al. used
RSM method to investigate the effect of input p
SR in EDM of AISI D2 tool steel. It was found that the
developed models can be used effectively in prediction of
responses. In this work, mathematical models have been
developed for relating the SR to machining parameters like
discharge current, pulse-on time and pulse
varied over wide range from roughing region to nearly
finishing conditions[7]. Kuppan at el. derived mathematical
model for MRR and average SR of deep hole drilling of
Inconel 718. The experiments were planned usin
RSM was used to model the same. It revealed that MRR is
more influenced by peak current and duty factor, and the
parameters were optimized for maximum MRR with the
desired SR value using desirability function approach [8].
Jaharah et al. investigated the machining performance such as
SR, electrode wear rate and MRR with copper electrode and
AISI H3 tool steel work piece and the input parameters taken
are Ip, Ton, and Toff. The optimum condition for SR was
obtained at low Ip, low Ton, and Toff and concluded that the
Ip was the major factor effecting both the responses, MRR and
SR [9]. Chiang had explained the influences of Ip, Ton, duty
factor and voltage on the responses; MRR, electrodes wear
ratio, and SR. The experiments were planned according t
CCD and the influence of parameters and their interactions
were investigated using ANOVA. A mathematical model was
developed and claimed to fit and predict MRR accurately with
a 95% confidence. Results show that the main two significant
factors affecting the response are the Ip and the duty
factor[10].
Literature reviewed shows that, the two
factors on the value of the SR are the discharge current and
the duty factor. Statistical models have been developed using
RSM based on experimental results considering the machining
parameters, viz., amplitude of vibration (A, µm), peak current
(IP, A), pulse-on time (Ton, μs), machining time (Mt, min.)
and flushing pressure (Pf, kgf/cm2) as independent variables.
Finally, an attempt has been made to obtain optimum
machining conditions with respect to SR parameter considered
in the present study with the help of response optimization
technique.
IJRET: International Journal of Research in Engineering and Technology eISSN:
__________________________________________________________________________________________
2013, Available @ http://www.ijret.org
range[3]. Sahoo et al. demonstrated the effect of most
for different work
piece materials in EDM [4]. Kanagarajan et al. developed
influencing process
parameters in EDM of WC/30% Co composites. The RSM
methodology is used to identify the most influential
parameters for maximizing metal removal rate and for
[5]. Shabgard and Shotorbani suggested
, TWR and SR to
approach is used to determine the
relationship between various process parameters and
machining criteria of FW4 welded steel[6]. Pradhan et al. used
RSM method to investigate the effect of input parameters on
SR in EDM of AISI D2 tool steel. It was found that the
developed models can be used effectively in prediction of
responses. In this work, mathematical models have been
developed for relating the SR to machining parameters like
on time and pulse-off time which
varied over wide range from roughing region to nearly
finishing conditions[7]. Kuppan at el. derived mathematical
model for MRR and average SR of deep hole drilling of
Inconel 718. The experiments were planned using CCD and
RSM was used to model the same. It revealed that MRR is
more influenced by peak current and duty factor, and the
parameters were optimized for maximum MRR with the
desired SR value using desirability function approach [8].
gated the machining performance such as
SR, electrode wear rate and MRR with copper electrode and
and the input parameters taken
are Ip, Ton, and Toff. The optimum condition for SR was
concluded that the
Ip was the major factor effecting both the responses, MRR and
SR [9]. Chiang had explained the influences of Ip, Ton, duty
factor and voltage on the responses; MRR, electrodes wear
ratio, and SR. The experiments were planned according to a
CCD and the influence of parameters and their interactions
were investigated using ANOVA. A mathematical model was
developed and claimed to fit and predict MRR accurately with
a 95% confidence. Results show that the main two significant
ng the response are the Ip and the duty
main significant
are the discharge current and
the duty factor. Statistical models have been developed using
tal results considering the machining
parameters, viz., amplitude of vibration (A, µm), peak current
s), machining time (Mt, min.)
and flushing pressure (Pf, kgf/cm2) as independent variables.
to obtain optimum
machining conditions with respect to SR parameter considered
in the present study with the help of response optimization
2. EXPERIMENTATION
The method of assisting EDM process with discontinuous
ultrasonic vibrations is designed and developed. The ultrasonic
vibrations of 25000 Hz are achieved through developed Piezo
electric transducer. A piezo
EDM machine to give continuous and discontinuous ultrasonic
vibrations to work piece at frequency of 25000 Hz with
amplitude range of 1 µm to 10 µm.
Fig- 1: Line diagram of UEDM set
An ultrasonic panel is used to control the amplitude and mode
(continuous and discontinuous) of vibration. In case of
discontinuous vibrations, the high frequency electrical impulse
from the generator to the transducer is discontinuous but
interval time is adjusted in terms of frequency
finally frequency is maintai
the schematic diagram of the develo
Figure 2 shows the circuit diagram of discontinuous vibration
through piezoelectric transducer.
study is Aluminum alloy 6063 with cylindrical shape
(Diameter 10mm and Height 30mm). Table 1 shows the
chemical composition of work
Fig- 2: Circuit diagram of discontinuous vibration
eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
728
2. EXPERIMENTATION
The method of assisting EDM process with discontinuous
ultrasonic vibrations is designed and developed. The ultrasonic
vibrations of 25000 Hz are achieved through developed Piezo-
electric transducer. A piezo-electric transducer is attached with
to give continuous and discontinuous ultrasonic
vibrations to work piece at frequency of 25000 Hz with
amplitude range of 1 µm to 10 µm.
Line diagram of UEDM set-up
An ultrasonic panel is used to control the amplitude and mode
nd discontinuous) of vibration. In case of
discontinuous vibrations, the high frequency electrical impulse
from the generator to the transducer is discontinuous but
interval time is adjusted in terms of frequency-adjustment and
finally frequency is maintained at 25000Hz. Figure 1 shows
schematic diagram of the developed UEDM set-up and
Figure 2 shows the circuit diagram of discontinuous vibration
through piezoelectric transducer. The work piece used for
study is Aluminum alloy 6063 with cylindrical shape
(Diameter 10mm and Height 30mm). Table 1 shows the
chemical composition of work-piece used for study.
Circuit diagram of discontinuous vibration
3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 729
Table -1: Chemical Composition of Al 6063
Element %
Si 0.3
Fe 0.35
Cu 0.09
Mn 0.1
Mg 0.7
Zn 0.1
Ti 0.1
Cr 0.1
Al 98.16
The experiments are conducted using the commercial Elektra
EMS 5535 model Die Sinking Ram EDM. For each
experiment, a separate Copper electrode (Diameter 5mm and
Height 30mm) has been used.
3. DESIGN OF EXPERIMENTS
The design factors, response variable as well as the
methodology employed for the experimentation is described
below.
3.1 Design Factor
The design factors considered in the present work were
amplitude of vibration, peak current, pulse-on time, machining
time and flushing pressure. The selection of these five factors
has been made because they are the most important and
widely used by researchers in the die sinking EDM field.
3.2 Response Variables
SR is the measure of the fine surface irregularities in the
surface texture. These are the results of the EDM process
employed to create the surface. SR is related as the arithmetic
average deviation of the surface valleys and peaks expressed
in micro-meters.
The parameter mostly used for general SR is SR. It measures
average roughness by comparing all the peaks and valleys to
the mean line, and then averaging them all over the entire cut-
off length. Cut-off length is the length for which the stylus is
dragged across the surface. A longer cut-off length will give a
more average value, and a shorter cut-off length might give a
less accurate result over a shorter stretch of surface. In this
work, the SR is measured by Mitutoyo surftest SJ-400. The
surf test is a shop–floor type SR measuring instrument, which
traces the surface of various machine parts and calculates the
SR based on roughness standards, and displays the results in
μm. The work piece is attached to the detector unit of the SJ-
400 which traces the minute irregularities of the work piece
surface. The vertical stylus displacement during the trace is
processed and digitally displayed on the display of the
instrument. The surf test has a resolution varying from 0.01
μm to 0.4 μm depending on the measurement range. The
roughness values are taken by averaging at least three
measurements per specimen at different locations of
specimens.
3.3 Factorial Design Employed
Experiments were designed on the basis of design of
experiments. The design finally chosen was a factorial design
24 with six central points, consequently carrying out a total of
32 experiments. Based on the CCD, experiments were
conducted to develop empirical models for SR in terms of the
five input variables: amplitude of vibration, peak current,
pulse-on time, machining time and flushing pressure. Each
input variable (factor) was varied over five levels: ±1, 0 and
±α. Table 2 shows the relationship between the machining
parameters and their corresponding selected variation levels,
taking into account the entire range of machine parameters.
The experimental data as shown in Table 2 is utilized to obtain
the relation between the EDM process parameters and the
output SR. RSM utilizes statistical design of experiment
technique and least-square fitting method in the model
generation phase. An equation consisting of values of a
dependent response variable and independent variables is
derived for SR characteristics.
Table -2: Process Parameters and their Levels
S.
No.
Symbol and
Units
Parameters Levels
(-2) (-1) (0) (+1) (+2)
1 A (µm) Amplitude of Vibration 0 2 4 6 8
2 IP (A) Peak Current 5 15 25 35 45
3 Ton (µs) Pulse-on Time 50 100 150 200 250
4 Mt (Min.) Machining Time 20 25 30 35 40
5 Pf (Kgf/cm2) Flushing Pressure 0.2 0.4 0.6 0.8 1.0
4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
__________________________________________________________________________________________
Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 730
Regression equations are found out using software for
statistical analysis called “Design Expert (DX-8)”. ANOVA
and Fisher’s statistical test (F-test) is performed to check the
adequacy of the model as well as significance of individual
parameters.
4. RESPONSE SURFACE METHDOLOGY
Response surface methodology is a collection of mathematical
and statistical techniques that are useful for modelling and
analysis of problems in which a response of interest is
influenced by several variables and the objective is to optimize
the response. Response Surface Method adopts both
mathematical and statistical techniques [11,12]. RSM helps in
analyzing the influence of the independent variables on a
specific dependent variable (response) by quantifying the
relationships amongst one or more measured responses and
the vital input factors. The first step in RSM is to find a
suitable approximation for the true functional relationship
between response of interest ‘y’ and a set of controllable
variables {x1, x2, ……xn}. Usually when the response
function is not known or non-linear, a second order model is
utilized [13] in the form:
Y=
r
2
2ji
jiij
k
1i
2
iii
k
1i
ii exxbxbxbb ±+++ ∑∑∑ =<==
o
….1
Where, ε represents the noise or error observed in the response
y such that the expected response is (y -ε ) and b’s are the
regression coefficients to be estimated. The least square
technique is being used to fit a model equation containing the
input variables by minimizing the residual error measured by
the sum of square deviations between the actual and estimated
responses. The calculated coefficients or the model equations
however need to be tested for statistical significance and thus
the test is performed.
4.1 Significance Test of the Regression Model
Analysis of Variance (ANOVA) is used to check the adequacy
of the model for the responses in the experimentation. ANOVA
calculates the F-ratio, which is the ratio between the
regression mean square and the mean square error. The F-
ratio, also called the variance ratio, is the ratio of variance due
to the effect of a factor (the model) and variance due to the
error term. This ratio is used to measure the significance of the
model under investigation with respect to the variance of all
the terms included in the error term at the desired significance
level (α). If the calculated value of F-ratio is higher than the
tabulated value of F-ratio for roughness, then the model is
adequate at desired α level to represent the relationship
between machining response and the machining parameters.
5. EXPERIMENTAL RESULTS
Table 3 shows the design matrix developed for the proposed
model as well as the machining characteristics values obtained
in the experiments for SR.
5.1 Model Adequacy Test for SR
The ANOVA and Fisher's statistical test (F- test) were
performed to check the adequacy of the model as well as the
significance of individual parameters. Table 4 shows the pre-
ANOVA model summary statistics for SR. It can be seen that
standard deviation of quadratic model is 0.49, which is
much better as compared with lower order model for R-
squared. Hence the quadratic model suggested is most
appropriate. Table 5 shows the variance analysis results of the
proposed model of SR. The ANOVA Table includes Sum of
Squares (SS), Degrees of Freedom (DF), Mean Square (MS),
F-value and P- value. The MS was obtained by dividing the
SS of each of the sources of variation by the respective DF.
The P-value is the smallest level of significance at which the
data are significant. The F-value is the ratio of MS of the
model terms to the MS of the residual. In this analysis,
insignificant model terms were eliminated to adjust the fitted
mathematical model. As seen from Table 5, the P-values for
developed model of SR is less than 0.0001, which indicates
that model is significant at 92% confidence level.
Table -3: Experimental conditions and results of response characteristics for SR
Std.
Order
Run
order
Factor A Factor B Factor C Factor D Factor E Response
Amplitude of
Vibration
(µm)
Peak
Current
(A)
Pulse-on
time
(µs)
Time of
Machining
(min.)
Flushing
Pressure
(kg/cm2)
Surface
Roughness
(µm)
1 15 2 15 100 25 0.8 7.69
2 32 6 15 100 25 0.4 10.63
3 4 2 35 100 25 0.8 10.1
4 6 6 35 100 25 0.4 10
5 26 2 15 200 25 0.8 10.38
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E-Flushing Pressure 0.12 1 0.12 0.38 0.5468
AD 0.78 1 0.78 2.37 0.1442
AE 3.02 1 3.02 9.20 0.0084
BD 1.40 1 1.40 4.26 0.0567
BE 3.21 1 3.21 9.79 0.0069
CE 2.68 1 2.68 8.17 0.0120
DE 0.29 1 0.29 0.88 0.3629
A2 10.79 1 10.79 32.90 <0.0001
B2 15.14 1 15.14 46.14 <0.0001
C2 5.03 1 5.03 15.33 0.0014
D2 2.20 1 2.20 6.72 0.0204
E2 3.52 1 3.52 10.74 0.0051
Residual 2.69 11 0.24
Lack of Fit 1.55 6 0.26 1.66 0.3006 Not Significant
Pure Error 1.44 5 0.23
Cor Total 60.84 31
It was noted that MS of the model (3.49) is many times larger
than MS of the residual (0.24), thus the computed F-value of
the model (F=3.49/0.24) of 14.54 implies that the model is
significant.
Table 6 shows the R-Squared (R2), "Adjusted R-Squared
(Adj. R2)" and "Predicted R- Squared (Pred. R2)" statistics.
The R-Squared is defined as the ratio of variability explained
by the model to the total variability in the actual data and is
used as a measure of the goodness of fit. The more R2
approaches unity, the better the model fits the experimental
data. For instance, the obtained value of 0.9191 for R2 in the
case of SR (Table 6) implies that the model explains variations
in the SR to the extent of 91.91% in the current experiment
and thus the model is adequate to represent the process.
The "Predicted R2" of 0.5433 is in reasonable agreement with
the "Adjusted R2" of 0.8328 because the difference between
the adjusted and predicted R2 is within 0.28 as recommended
for model to be adequate.
The value of Pred. R2" of 0.5433 indicates the prediction
capability of the regression model. It means that the model
explains about 54.33% of the variability in predicting new
observations as compared to the 91.91% of the variability in
the original data explained by the least square fit. "Adeq
Precision" measures the signal to noise ratio. A ratio greater
than 4 is desirable. The ratio of 15.697 indicates an adequate
signal. Thus, the overall prediction capability of the model
based on these criteria seems very satisfactory.
Table -6: Post ANOVA Model adequacy for SR
R-Squared 0.9191
Adj R-Squared 0.8328
Pred R-Squared 0.5433
Adeq Precision 15.697
6. ANALYSIS AND DISCUSSION OF RESULTS
The set of experiments is designed and conducted by
employing RSM using discontinuous nature of vibration. The
selection of appropriate model and the development of
response surface models have been carried out by using
statistical software “Design Expert (DX-8)”. The regression
equations for the selected model are obtained for the response
characteristics, viz., SR. These regression equations are
developed using the experimental data presented in Table 3.
The response surfaces are plotted to investigate the effect of
input process parameters, amplitude of vibration, peak current,
pulse-on time, machining time and flushing pressure together
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 733
with their second order interaction on the response
characteristics. The Analysis of Variance (ANOVA) is
performed to statistically analyze the results.
6.1 Selection of Adequate Model
Table 7 displays different tests to select the adequate model to
be fit for SR. The “sequential model sum of squares” test in
each Table7 shows how the terms of increasing complexity
contribute to the model. It can be observed that for all the
responses/characteristics, the quadratic model is appropriate
[because Prob>F Value, 0.0001 (Table 7), is less than 0.05].
The addition of cubic terms does not significantly improve the
lack of fit because these terms are aliased for CCD (even if
these were significant). The “lack of fit” test compares the
residual error to the pure error from the replicated design
points.
Table -7: Selection of Adequate Model for surface roughness
1 Sequential Model sum of Squares
Source Sum of Squares DOF Mean Square F-value Prob > F
Mean 3283.34 1 3283.34
Linear 6.21 5 1.24 0.59 0.7065
2FI 13.61 10 1.36 0.53 0.8441
Quadratic 38.32z 5 7.66 31.33 <0.0001 Suggested
Cubic 0.92 5 0.18 0.63 0.6867 Aliased
Residual 1.77 6 0.29
Total 3344.17 32 104.51
2 Lack of Fit Tests
Source Sum of Squares DOF Mean Square F-Value Prob > F
Linear 53.48 21 2.55 11.16 0.0070
2FI 39.87 11 3.62 15.89 0.0034
Quadratic 1.55 6 0.26 1.13 0.4555 Suggested
Cubic 0.63 1 0.63 2.74 0.1587 Aliased
Pure Error 1.14 5 0.23
3 Model summary Statistics
Source Standard Deviation R-Squared Adjusted R-
Squared
Predicted R-
Squared
PRESS
Linear 1.45 0.1021 -0.0705 -0.3993 85.13
2FI 1.60 0.3259 -0.3061 -0.5057 91.60
Quadratic 0.49 0.9558 0.8754 0.3309 40.70 Suggested
Cubic 0.54 0.9710 0.8500 -10.1824 680.29 Aliased
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The Table 7 indicates that the quadratic model in all the
response characteristics does not show significant lack of fit,
hence the adequacy of quadratic model is confirmed. Another
test “model summary statistics” given in the following Table
further confirms that the quadratic model is the best to fix as it
exhibits low standard deviation, high “R-Squared” values, and
a low “PRESS” (Adeq Precision).
fLN = N–1 …2
Where,
fLN = Total degrees of freedom of an OA
LN = OA designation
N = Number of trials
The regression coefficients of the second order equation
(Equation 3) are obtained by using the experimental data in
Table 3. The regression equations for the response
characteristic as a function of five process parameters
considered in this experiment are given below. The
insignificant coefficients (identified from ANOVA) have been
omitted from the equation.
SR = +33.28–1.24*A+0.15*IP–0.06*Po–0.73*Mt–
30.15*Pf–8.21E–003*A*IP+2.66E–003*A*Ton–
0.02*A*M+1.08*A*Pf–4.03E–004*IP*Ton+5.91E–
003*P*Mt+0.22*IP*Pf–8.25E–
005*Ton*Mt+0.04*Ton*Pf+0.13*Mt*Pf+0.15*A2–
7.18E–003*IP2+1.65E–
004*Ton
2+0.01*Mt
2+8.66*Pf
2 3
Where A: Amplitude of vibration, IP: Peak Current, Ton:
Pulse-on Time, Mt: Machining Time, Pf: Flushing Pressure.
Using this equation, the response surfaces have been plotted to
study the effect of process parameters on the performance
characteristics.
Figure 3 shows the combined effect of amplitude of vibration
and peak current on SR. At the lower value of peak current
against amplitude of vibration, the SR is less but it increases
with increase in the peak current. SR decreases with increase
in the amplitude of vibration with respect to peak current up to
a certain level. This happens due to intensity of vibration, as
amplitude of vibration at its lower level allows less debris to
get removed and at higher level, the ideal time is more which
result in increased surface roughness.
Fig -3: Response Surface for the Combined Effect of
Amplitude of Vibration and Peak Current on SR
Figure 4 shows the combined effect of amplitude of vibration
and pulse-on time on SR. The amplitude of vibration and pulse
on-time have similar effect on SR..SR is minimum at the
average value of both parameter. The response increases when
the value of both factors increase, as with the increased
amplitude of vibration, more craters are created at the work
piece and with increased pulse on time as lesser time is
available to eject the eroded material from working zone.
Fig -4: Response Surface for the Combined Effect of
Amplitude of Vibration and Pulse-on Time on SR
Figure 5 shows the combined effect of amplitude of vibration
and machining time on SR. Lower value of machining time
and amplitude of vibration cause lesser SR while SR increases
with their increasing values, as the machining time is
increased, deeper craters are formed, which result in rougher
surfaces. The maximum value of response occurs at the lower
value of machining time and higher value of amplitude of
vibration.
15.00
20.00
25.00
30.00
35.00
2.00
3.00
4.00
5.00
6.00
8
8.5
9
9.5
10
10.5
SurfaceRoughness
A: Amplitude of Vibration
B: Peak Current
100.00
125.00
150.00
175.00
200.00
2.00
3.00
4.00
5.00
6.00
8
9
10
11
12
SurfaceRoughness
A: Amplitude of Vibration
C: Pulse-on Time
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Fig -5: Response Surface for the Combined Effect of
Amplitude of Vibration and Machining Time on SR
Figure 6 shows the combined effect of amplitude of vibration
and flushing pressure on SR. At higher values of flushing
pressure and amplitude of vibration, SR is much more as
compared to the any other values.. On the lower value of
amplitude of vibration and increasing value of flushing
pressure the SR decrease while at the higher value of
amplitude of vibration with increasing value of flushing
pressure the SR increase. The SR is higher at lower and higher
value of amplitude of vibration with respect to flushing
pressure, while SR decreases at its average value.
Fig -6: Response Surface for the Combined Effect of
Amplitude of Vibration and Flushing Pressure on SR
Figure 7 shows the combined effect of peak current and pulse-
on time on SR. With rise in peak current, SR increases up to a
certain level and then decreases. At lower value of peak
current and increasing value of pulse on time, SR is much
lower then any other level. The response is maximum at
higher value of pulse on time and average value of peak
current. The pulse on-time causes the increased size of spark
crater with aid of peak current which results in increased SR.
Fig -7: Response Surface for the Combined Effect of Peak
Current and Pulse-on Time on SR
Figure 8 shows the combined effect of peak current and
machining time on SR. The SR decreases when the machining
time is maximum and peak current is minimum or vice versa.
The SR is maximum at average value of peak current and
higher value of machining time. The higher machining time
and peak current gave less time for the removal of debris
which results in increase in SR.
Fig -8: Response Surface for the Combined Effect of Peak
Current and Machining Time on SR
Figure 9 shows the combined effect of peak current and
flushing pressure on SR. The increase in peak current with
respect to flushing pressure increases the SR. The SR is lesser
when the flushing pressure is increasing and peak current is
minimum. When the peak current increases, the size of crater
increases which causes more erosion of the work piece. This
eroded work piece can only be removed with higher flushing
pressure otherwise the SR would increase.
25.00
27.00
29.00
31.00
33.00
35.00
2.00
3.00
4.00
5.00
6.00
8
9
10
11
12
13
SurfaceRoughness
A: Amplitude of Vibration
D: Machining Time
0.40
0.50
0.60
0.70
0.80
2.00
3.00
4.00
5.00
6.00
8
9
10
11
12
13
SurfaceRoughness
A: Amplitude of Vibration
E: Flushing Pressure
100.00
125.00
150.00
175.00
200.00
15.00
20.00
25.00
30.00
35.00
8
9
10
11
12
13
SurfaceRoughness
B: Peak Current
C: Pulse-on Time
25.00
27.00
29.00
31.00
33.00
35.00
15.00
20.00
25.00
30.00
35.00
8
9
10
11
12
13
SurfaceRoughness
B: Peak CurrentD: Machining Time
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 736
Fig -9: Response Surface for the Combined Effect of Peak
Current and Flushing Pressure on SR
Figure 10 shows the combined effect of pulse-on time and
machining time on SR. The SR is maximum at higher values
of pulse on time and machining time. The response is
minimum at the average values of both parameters. The pulse
on-time and machining time collectively effect the SR because
machining time is totally dependant on pulse on-time.
Fig -10: Response Surface for the Combined Effect of Pulse-
on Time and Machining Time on SR
Figure 11 shows the effect of pulse-on time and flushing
pressure on SR. SR increases at lower and higher levels of
both parameters collectively. SR decreases at minimum value
of pulse on time and higher value of flushing pressure or vice
versa. Pulse on time allows the current to erode the work piece
by heating it. The higher flushing pressure quench the work
piece while the lower did not remove debris properly, which
result higher SR at their higher and lower level.
Fig -11: Response Surface for the Combined Effect of Pulse-
on Time and Flushing Pressure on SR
Figure 12 shows the combined effect of machining time and
flushing pressure on SR. The SR is maximum when the values
of both the parameters are at higher level. With increase in
flushing pressure with respect to machining time, the SR
decreases. The increase in machining time with flushing
pressure causes, firstly reduction and then increase in SR. The
more flushing pressure with less machining time cause proper
elimination of debris which result in lower SR.
Fig -12: Response Surface for the Combined Effect of
Machining Time and Flushing Pressure on SR
CONCLUSIONS
Using Al6063 as work piece, the effects on SR is found by
five parameters i.e. amplitude of vibration, pulse-on time,
peak current, machining time and flushing pressure by using
RSM. It is concluded that all the five parameters have their
different effect on SR when used with each other. The
intensity of SR may be reduced by increasing flushing
pressure as this leads to easy removal of debris. Also, SR
increases with increase in amplitude of vibration, peak current
and pulse on-time.
0.40
0.50
0.60
0.70
0.80
15.00
20.00
25.00
30.00
35.00
8
9
10
11
12
13
SurfaceRoughness
B: Peak Current
E: Flushing Pressure
25.00
27.00
29.00
31.00
33.00
35.00
100.00
125.00
150.00
175.00
200.00
8
9
10
11
12
13
SurfaceRoughness
C: Pulse-on TimeD: Machining Time
0.40
0.50
0.60
0.70
0.80
100.00
125.00
150.00
175.00
200.008
9
10
11
12
13
SurfaceRoughness
C: Pulse-on Time
E: Flushing Pressure
0.40
0.50
0.60
0.70
0.80
25.00
27.00
29.00
31.00
33.00
35.00
8
9
10
11
12
13
SurfaceRoughness
D: Machining Time
E: Flushing Pressure
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Volume: 02 Issue: 11 | Nov-2013, Available @ http://www.ijret.org 737
So, it is concluded that at lower values of amplitude of
vibration, peak current & pulse on-time and higher value of
flushing pressure leads to reduction in SR.
REFERENCES
[1]. Russell V. Lenth, “Response-Surface Methods in R, Using
RSM,” Journal of Statistical Software, Vol. 32 (7), 2009
[2]. M.R. Shabgard and R.M. Shotorbani, “Mathematical
Modeling of Machining Parameters in Electrical Discharge
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[3]. K. M. Iqbal Asif and Ahsan Ali Khan, “Modeling and
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[4]. P. Sahoo, Routara B.C. and A. Bandyopadhyay,
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BIOGRAPHIES
Dr. Jujhar Singh has completed his Ph.D.
in 2012 from PEC University of
Technology, Chandigarh, he received his
B.Tech. (Mechanical Engineering) in 2000
from Guru Nanak Dev Engineering
College, Ludhiana, India and M.E.
(Rotodynamic Machines) in 2004 from
PEC University of Technology,
Chandigarh, India. He has 12 years of experience in teaching
and research. His area of research interest includes modeling
and analysis and optimization of manufacturing processes. He
has published more than 11 research papers in international
Journal/Conferences. He is life member of ISTE. Currently he
is working as Associate Professor and Vice-Principal with
Rayat and Bahra Institute of Engineering and Bio-Technology,
Kharar, Punjab, India.
Sukhvir Singh is a student of M.Tech
(Regular) in Rayat and Bahra Institute of
Engineering and Bio-Technology, Kharar,
Punjab, India. He received his B.Tech
(Mechanical Engineeering) from Rayat and
Bahra Institute of Engineering and Bio-
Technology, Kharar, Punjab, India in the
year 2012. His area of research interest
includes optimization of machining processes.
Gurpreet Singh is a student of M.Tech
(Regular) in Rayat and Bahra Institute of
Engineering and Bio-Technology, Kharar,
Punjab, India.. He received his degree in
Mechanical Engineering in 2012 from
Rayat and Bahra Institute of Engineering
and Bio-Technology, India, which is
affiliated to the Punjab Technical
University, India. He has been a dedicated,
consistent and hardworking student throughout his studies. He
has keen interest in the machining processes with a main focus
on the optimization techniques involved in it.