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.
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.
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
This paper discuss of literature review of EDM and ANNOVA Technology used in on CNC. Today CNC technology has major contribution in i ndustries. CNC machines are main platform in the contribution of good quality products in industries. Basically CNC machines are automated operating machines which are based on code letters,numbers and special characters. The numerical data required for manufacturin g a part provided by machine is called CNC (Computer Numerical Controlled). To remain successful in today�s competitive market,the manufacturers should rely on their Engineer s and production professionals for quick and effective manufacturing setup and also to achie ve Quality products. The machining process on a CNC Milling is programmed by speed,feed rate,and cutting depth,which are frequently determined based on the job s hop experiences However,the machine performance and the product characteristics are not guaranteed to be acceptable.
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 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.
Parametric Optimization of Electrochemical Machining Using Signal-To-Noise (S...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
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 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.
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.
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
This paper discuss of literature review of EDM and ANNOVA Technology used in on CNC. Today CNC technology has major contribution in i ndustries. CNC machines are main platform in the contribution of good quality products in industries. Basically CNC machines are automated operating machines which are based on code letters,numbers and special characters. The numerical data required for manufacturin g a part provided by machine is called CNC (Computer Numerical Controlled). To remain successful in today�s competitive market,the manufacturers should rely on their Engineer s and production professionals for quick and effective manufacturing setup and also to achie ve Quality products. The machining process on a CNC Milling is programmed by speed,feed rate,and cutting depth,which are frequently determined based on the job s hop experiences However,the machine performance and the product characteristics are not guaranteed to be acceptable.
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 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.
Parametric Optimization of Electrochemical Machining Using Signal-To-Noise (S...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
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 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.
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.
Optimization of machining parameters of Electric Discharge Machining for 202 ...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
This document summarizes a study that used the Taguchi method to optimize drilling parameters for minimizing surface roughness when drilling mild steel. Experiments were conducted using an L27 orthogonal array to examine the effects of cutting speed, feed rate, and point angle on surface roughness. Analysis of the experimental results found that the lowest surface roughness was achieved with a low cutting speed, low feed rate, and medium point angle. Feed rate was found to be the most significant factor influencing surface roughness, followed by cutting speed. The optimal combination of drilling parameters to minimize surface roughness in mild steel is a cutting speed of 7 m/min, feed rate of 0.035 mm/rev, and point angle of 90 degrees.
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.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
This document presents an analysis of surface roughness characteristics during dry turning of medium carbon steel EN19. Experiments were conducted using a Taguchi L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on the surface roughness parameters Ra, Rq, and Rz. Grey relational analysis was used to determine the optimal process parameters that minimize all response variables. Regression models were developed to predict the surface roughness, which showed high correlation. Cutting speed was found to have the greatest influence on surface roughness based on ANOVA analysis.
performance study of electrochemical machining on metal matrix compositeNEERAJKUMAR1898
The document discusses performance studies of electrochemical machining (ECM) on metal matrix composites. It describes fabricating five different aluminum matrix composites using stir casting, including an Al 6061 alloy reinforced with 6% graphite and an Al 6061 alloy reinforced with 5% silicon carbide and 5% graphite. Experiments were conducted using Taguchi's design of experiments to determine the optimal ECM process parameters of voltage, electrolyte concentration, and frequency for maximizing material removal rate and minimizing overcut of the composites.
IRJET- Tensile and Shear Strength Approximate Prediction of Friction Surf...IRJET Journal
This document discusses using artificial neural networks (ANN) to predict the tensile and shear strength of tool steel coatings deposited through friction surfacing. Friction surfacing is used to deposit coatings on materials and has various industrial applications. An experiment was conducted to deposit tool steel coatings on low carbon steel using different levels of friction pressure, rotational speed, and welding speed. Tensile and shear strength tests were performed on the coatings. ANN models using a feedforward neural network (FFNN) structure were developed and trained on the experimental data to predict coating tensile and shear strength based on the friction surfacing process parameters. The ANN models provide a way to understand and optimize the relationship between mechanical properties and processing
Optimization of machining parameters in edm of cfrp composite using taguchi t...IAEME Publication
1. The document summarizes a study that used Taguchi methods to optimize machining parameters for electrical discharge machining (EDM) of carbon fiber reinforced plastic (CFRP) composite material.
2. The study investigated the effects of gap voltage, discharge current, and pulse-on time on surface roughness. Experiments were conducted using an L9 orthogonal array.
3. Analysis of variance (ANOVA) and signal-to-noise ratios were used to analyze the results. It was found that discharge current had the most significant influence on surface roughness, and confirmation experiments validated the optimum parameters identified.
Optimization of process parameters in drilling of aisi 1015 steel for exit bu...IAEME Publication
The document analyzes and optimizes drilling parameters to minimize burr size in drilling AISI 1015 steel. Response surface methodology and Taguchi methods were used. Speed, feed, drill diameter, and point angle were parameters varied, and burr height and thickness were responses. Central composite design was used. Optimal parameters for minimum burr height were found to be 28 m/min speed, 0.1 mm/rev feed, 20 mm diameter, and 135° point angle. Optimal parameters for minimum burr thickness were 16 m/min speed, 0.05 mm/rev feed, 4 mm diameter, and 142° point angle.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
EXPERIMENTAL INVESTIGATION OF PCM USING RESPONSE SURFACE METHODOLOGY ON SS316...IAEME Publication
This document describes an experimental investigation of photochemical machining (PCM) process parameters on SS316L steel using response surface methodology. 20 experiments were conducted using a center composite design to study the effect of time, temperature, and etchant concentration on the undercut response. A regression model was developed relating the undercut to the process parameters. Minimum undercut of 0.0815mm was observed at 63.99°C temperature, 769.69 gm/L concentration, and 46.96 minutes etching time. Statistical analysis showed time and temperature had significant effects on undercut.
Study of the Effects of Process Parameters on Tool Wear Rate in Electrical Di...ijtsrd
EDM machines are used to cut conductive metals of any hardness or that are difficult or impossible to cut with traditional methods. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researchers and practicing engineers for a very long time. This paper introduces the research results of tool wear rate of SKD11 steel after EDM. The influence of the process paramaters to the surface roughness Ra is surveyed and the optimal value Ra Ratoiuu also be established. The process parameters current I , pusle on time ton , pulse off time tof and voltage is used in research on SR in EDM. Taguchi method is used in this study. Minh - Nguyen Duc | Tai - Bui Tien "Study of the Effects of Process Parameters on Tool Wear Rate in Electrical Discharge Machining by Taguchi Method" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29266.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29266/study-of-the-effects-of-process-parameters-on-tool-wear-rate-in-electrical-discharge-machining-by-taguchi-method/minh---nguyen-duc
This document summarizes a study that investigated the effect of process parameters on machining EN31 steel using electrical discharge machining (EDM). Experiments were conducted using different tool materials (copper, aluminum, and EN24), supply currents, flushing pressures, and pulse-on times. The experiments analyzed their influence on surface roughness, material removal rate, tool wear rate, and taper. The results of this study can help optimize the EDM process for machining EN31 steel.
This document summarizes a study that used Taguchi methodology and Grey Relational Analysis to optimize machining parameters for CNC end milling of stainless steel 304. The goals were to minimize surface roughness (Ra) and maximize material removal rate (MRR). Experiments were conducted using an L9 orthogonal array to test cutting speed, feed rate, and depth of cut at three levels. Response data was normalized and Grey Relational Coefficients were calculated to determine the optimal parameter combination. The analysis found that a cutting speed of 75 m/min, feed rate of 0.15 mm/rev, and depth of cut of 1.5 mm provided the best results for achieving the combined objectives of lower Ra and higher MRR.
Modeling of Morphology and Deflection Analysis of Copper AlloysIRJET Journal
This document discusses modeling the morphology and deflection analysis of copper alloys during thin wall machining. It presents an experimental investigation to determine optimal cutting conditions for machining thin walls of copper plates. The experiments used Taguchi methods to analyze the impact of cutting speed, feed rate, and depth of cut on surface roughness and part deflection. Analysis of variance (ANOVA) was then used to determine the correlation between these output responses and the cutting parameters, identifying the optimum conditions for thin wall machining of copper. The results showed that with appropriate process parameters, it is possible to end mill thin walls in copper as thin as 0.5mm with an aspect ratio of 48 and achieve a good surface finish and minimal deflection.
Analysis and optimization of machining process parametersAlexander Decker
This document analyzes machining process parameters like feed, cutting speed, and depth of cut to optimize surface roughness and metal removal rate when turning aluminum alloy and resin workpieces. Experiments were conducted using a response surface methodology. Mathematical models were developed relating the output responses to the input parameters. The models were found to accurately predict the surface roughness and metal removal rate. Optimization found the minimum surface roughness was 1.18 μm for aluminum alloy and 2.295 μm for resin, while the maximum metal removal rate was achieved at higher speeds, feeds, and depths of cut.
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 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
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
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.
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%.
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.
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.
Optimization of machining parameters of Electric Discharge Machining for 202 ...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
This document summarizes a study that used the Taguchi method to optimize drilling parameters for minimizing surface roughness when drilling mild steel. Experiments were conducted using an L27 orthogonal array to examine the effects of cutting speed, feed rate, and point angle on surface roughness. Analysis of the experimental results found that the lowest surface roughness was achieved with a low cutting speed, low feed rate, and medium point angle. Feed rate was found to be the most significant factor influencing surface roughness, followed by cutting speed. The optimal combination of drilling parameters to minimize surface roughness in mild steel is a cutting speed of 7 m/min, feed rate of 0.035 mm/rev, and point angle of 90 degrees.
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.
Analysis of Process Parameters in Dry Turning of Medium Carbon Steel En19 by ...IJERA Editor
This document presents an analysis of surface roughness characteristics during dry turning of medium carbon steel EN19. Experiments were conducted using a Taguchi L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on the surface roughness parameters Ra, Rq, and Rz. Grey relational analysis was used to determine the optimal process parameters that minimize all response variables. Regression models were developed to predict the surface roughness, which showed high correlation. Cutting speed was found to have the greatest influence on surface roughness based on ANOVA analysis.
performance study of electrochemical machining on metal matrix compositeNEERAJKUMAR1898
The document discusses performance studies of electrochemical machining (ECM) on metal matrix composites. It describes fabricating five different aluminum matrix composites using stir casting, including an Al 6061 alloy reinforced with 6% graphite and an Al 6061 alloy reinforced with 5% silicon carbide and 5% graphite. Experiments were conducted using Taguchi's design of experiments to determine the optimal ECM process parameters of voltage, electrolyte concentration, and frequency for maximizing material removal rate and minimizing overcut of the composites.
IRJET- Tensile and Shear Strength Approximate Prediction of Friction Surf...IRJET Journal
This document discusses using artificial neural networks (ANN) to predict the tensile and shear strength of tool steel coatings deposited through friction surfacing. Friction surfacing is used to deposit coatings on materials and has various industrial applications. An experiment was conducted to deposit tool steel coatings on low carbon steel using different levels of friction pressure, rotational speed, and welding speed. Tensile and shear strength tests were performed on the coatings. ANN models using a feedforward neural network (FFNN) structure were developed and trained on the experimental data to predict coating tensile and shear strength based on the friction surfacing process parameters. The ANN models provide a way to understand and optimize the relationship between mechanical properties and processing
Optimization of machining parameters in edm of cfrp composite using taguchi t...IAEME Publication
1. The document summarizes a study that used Taguchi methods to optimize machining parameters for electrical discharge machining (EDM) of carbon fiber reinforced plastic (CFRP) composite material.
2. The study investigated the effects of gap voltage, discharge current, and pulse-on time on surface roughness. Experiments were conducted using an L9 orthogonal array.
3. Analysis of variance (ANOVA) and signal-to-noise ratios were used to analyze the results. It was found that discharge current had the most significant influence on surface roughness, and confirmation experiments validated the optimum parameters identified.
Optimization of process parameters in drilling of aisi 1015 steel for exit bu...IAEME Publication
The document analyzes and optimizes drilling parameters to minimize burr size in drilling AISI 1015 steel. Response surface methodology and Taguchi methods were used. Speed, feed, drill diameter, and point angle were parameters varied, and burr height and thickness were responses. Central composite design was used. Optimal parameters for minimum burr height were found to be 28 m/min speed, 0.1 mm/rev feed, 20 mm diameter, and 135° point angle. Optimal parameters for minimum burr thickness were 16 m/min speed, 0.05 mm/rev feed, 4 mm diameter, and 142° point angle.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
EXPERIMENTAL INVESTIGATION OF PCM USING RESPONSE SURFACE METHODOLOGY ON SS316...IAEME Publication
This document describes an experimental investigation of photochemical machining (PCM) process parameters on SS316L steel using response surface methodology. 20 experiments were conducted using a center composite design to study the effect of time, temperature, and etchant concentration on the undercut response. A regression model was developed relating the undercut to the process parameters. Minimum undercut of 0.0815mm was observed at 63.99°C temperature, 769.69 gm/L concentration, and 46.96 minutes etching time. Statistical analysis showed time and temperature had significant effects on undercut.
Study of the Effects of Process Parameters on Tool Wear Rate in Electrical Di...ijtsrd
EDM machines are used to cut conductive metals of any hardness or that are difficult or impossible to cut with traditional methods. The problem of arriving at the optimum levels of the operating parameters has attracted the attention of the researchers and practicing engineers for a very long time. This paper introduces the research results of tool wear rate of SKD11 steel after EDM. The influence of the process paramaters to the surface roughness Ra is surveyed and the optimal value Ra Ratoiuu also be established. The process parameters current I , pusle on time ton , pulse off time tof and voltage is used in research on SR in EDM. Taguchi method is used in this study. Minh - Nguyen Duc | Tai - Bui Tien "Study of the Effects of Process Parameters on Tool Wear Rate in Electrical Discharge Machining by Taguchi Method" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-6 , October 2019, URL: https://www.ijtsrd.com/papers/ijtsrd29266.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/29266/study-of-the-effects-of-process-parameters-on-tool-wear-rate-in-electrical-discharge-machining-by-taguchi-method/minh---nguyen-duc
This document summarizes a study that investigated the effect of process parameters on machining EN31 steel using electrical discharge machining (EDM). Experiments were conducted using different tool materials (copper, aluminum, and EN24), supply currents, flushing pressures, and pulse-on times. The experiments analyzed their influence on surface roughness, material removal rate, tool wear rate, and taper. The results of this study can help optimize the EDM process for machining EN31 steel.
This document summarizes a study that used Taguchi methodology and Grey Relational Analysis to optimize machining parameters for CNC end milling of stainless steel 304. The goals were to minimize surface roughness (Ra) and maximize material removal rate (MRR). Experiments were conducted using an L9 orthogonal array to test cutting speed, feed rate, and depth of cut at three levels. Response data was normalized and Grey Relational Coefficients were calculated to determine the optimal parameter combination. The analysis found that a cutting speed of 75 m/min, feed rate of 0.15 mm/rev, and depth of cut of 1.5 mm provided the best results for achieving the combined objectives of lower Ra and higher MRR.
Modeling of Morphology and Deflection Analysis of Copper AlloysIRJET Journal
This document discusses modeling the morphology and deflection analysis of copper alloys during thin wall machining. It presents an experimental investigation to determine optimal cutting conditions for machining thin walls of copper plates. The experiments used Taguchi methods to analyze the impact of cutting speed, feed rate, and depth of cut on surface roughness and part deflection. Analysis of variance (ANOVA) was then used to determine the correlation between these output responses and the cutting parameters, identifying the optimum conditions for thin wall machining of copper. The results showed that with appropriate process parameters, it is possible to end mill thin walls in copper as thin as 0.5mm with an aspect ratio of 48 and achieve a good surface finish and minimal deflection.
Analysis and optimization of machining process parametersAlexander Decker
This document analyzes machining process parameters like feed, cutting speed, and depth of cut to optimize surface roughness and metal removal rate when turning aluminum alloy and resin workpieces. Experiments were conducted using a response surface methodology. Mathematical models were developed relating the output responses to the input parameters. The models were found to accurately predict the surface roughness and metal removal rate. Optimization found the minimum surface roughness was 1.18 μm for aluminum alloy and 2.295 μm for resin, while the maximum metal removal rate was achieved at higher speeds, feeds, and depths of cut.
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 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
Parametric optimization for cutting speed – a statistical regression modeling...IAEME Publication
This document presents an experimental study to optimize cutting speed in wire electrical discharge machining (WEDM) of EN-31 alloy steel. Experiments were conducted using a L27 orthogonal array to investigate the effects of eight machining parameters (pulse on time, pulse off time, peak current, spark gap voltage, wire feed rate, wire tension, servo feed, and dielectric flushing pressure) on cutting speed. Analysis of variance was used to determine the most significant parameters, and the optimal levels for maximizing cutting speed were found to be pulse on time at 128 μs, pulse off time at 53 μs, peak current at 230 A, spark gap voltage at 20 V, wire feed rate at 4 m/min, wire tension at
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.
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%.
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 document discusses a study on the effect of electrical discharge machining (EDM) parameters on high carbon-chromium steel. Central composite design was used to conduct experiments varying pulse on time, duty cycle, current, voltage gap, and pressure. Response variables of material removal rate, electrode wear rate, and surface roughness were analyzed. For material removal rate, the linear model best fit the data. Interaction effects best modeled electrode wear rate, with some parameters having high impact. The interaction model also best fit surface roughness data. Overall, the study used statistical methods to develop models relating EDM parameters to response variables for high carbon-chromium steel EDM.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
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.
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.
THE EFFECT OF DIFFERENT WIRE ELECTRODES ON THE MRR OF MS WORKPIECE USING WEDM...IAEME Publication
Wire electrical discharge machining (WEDM) is a specialized thermal machining process which is capable of accurate machining of parts which have varying hardness, complex shapes and sharp edges that are hard to be machined by the traditional machining processes. . Predictions on the
Material Removal Rate of workpieces in WEDM have been reported in the past. In the present study an analysis has been done to evaluate the Material Removal Rate of MS workpiece using WEDM process with different types of wire electrodes.
This document 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.
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.
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
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%.
Investigation of mrr in wedm for wc co sintered compositeIAEME Publication
The document investigates the influence of wire electrical discharge machining (WEDM) parameters on material removal rate when machining tungsten carbide-cobalt (WC-Co) sintered composite. Experiments were conducted using a response surface methodology with five control factors (pulse on-time, pulse off-time, peak current, servo voltage, and wire tension). The results were used to derive a mathematical model to predict material removal rate and optimize the WEDM process for machining WC-Co composite.
Optimization of Process Parameters in Wire Electrical Discharge Machining of ...IJERA Editor
Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts with varying hardness or complex shapes, which have sharp edges that are very difficult to be machined by the main stream machining processes. This practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal. Since the introduction of the process, WEDM has evolved from a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish quality. Metal matrix composites are advanced materials having high specific strength, good wear resistance, and high thermal expansion coefficient. To achieve this task, machining parameters such as pulse on time, pulse off time, peak current, servo voltage, wire feed, wire tension etc. of this process should be selected such that optimal value of their performance measures like Material Removal Rate (MRR), Surface Roughness (SR), Gap current, Dimensional deviation, etc. can be obtained or improved. In past decades, intensive research work had been carried out by different researchers for improvement and optimization of WEDM performance measures using various optimization techniques like Taguchi, Response Surface Methodology (RSM), Artificial Neural Network (ANN), Genetic Algorithm (GA), etc. This paper also highlights the feasibility of the different control strategies of obtaining the optimal machining conditions. This literature review helps to identify the suitable process parameters and their ranges in machining of metal matrix composites.
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 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.
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.
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A lubricant is a substance that reduces friction an d wear by providing a protective film between two moving surfaces. Good lubricants possess the proper ties such as low toxicity,high viscosity index,hi gh load carrying capacity,excellent coefficient of fr iction,good anti-wear capability,low emission int o the environment,high ignition temperature. So tribolog y related problems can be minimized by proper selection of lubricant from wear consideration. Tod ay,the depletion of reserves of crude oil,the gro wing prices of crude oil and concern about protecting th e environment against pollution have developed the interest towards environment-friendly lubricants. B ecause of these the purpose of this work is to eval uate the anti-wear characteristics of cottonseed oil and to check the suitability of cottonseed oil as a lu bricant for multi-cylinder engine. Four ball testing machin e is used for anti-wear testing as per ASTM D 4172. The wear preventive characteristic of cottonseed oi l is obtained by measuring wear scar diameter. The present study shows the potential of cotton seed oi l as an alternating lubricant.
Magnetic abrasive finishing is a machining process where the tooling allowance is remove by media wi th both magnetic and abrasive properties,with a magnetic f ield acting as a binder of a grain. Such machining falls into the category of erosion by abrasive suspension and lend itself to the finishing of any type of surface . The possibility of finishing complex surfaces is a spec ial benefit of this machining. Magnetic abrasive fi nishing process is most suitable for obtaining quality fini sh on metallic and non-metallic surfaces. Magnetic abrasive finishing used for complicated product finishing & Roughness and tolerance band achieved that is diffi cult using conventional machine process. The product dimension al requirement easily possible with taking trial wi th MAF parameters.
DESIGN OF INNER LID OF PRESSURE COOKER WITH CIRCULAR SHAPE HAVING STRAIGHT ED...ijiert bestjournal
Pressure cooker works hand in hand with the workin g woman. This is happening because of saving in tim e & energy. It means that pressure cooker become the in evitable item in kitchen. If we concentrate on the analysis of inner lid of the pressure cooker,it is highly bene ficial for everyone. That is why we concentrate on the possible shapes of lids of pressure cooker. The existing pre ssure cooker is of two type i. e. inner lid and out er lid type. The shape of existing inner lid pressure cooker is gene rally having elliptical shape. This shape is becaus e of locking & easy handling. The different alternatives are arisi ng. Out of which the best alternative found is the circular shape having straight edges at the edges. The modificatio n suggested here is also serving the same purposes as like the previous one. The advantages obtained here are also giving better result for locking,increase the hea t transfer area & saving in cooling time for food in measurable way as compare with the elliptical inner lid pressure c ooker. The result obtained will be definitely good comparing w ith the old model. Here simple & thermal stress ana lysis had been done by finite element method for the load & t emperature stability.
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
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Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
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Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
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Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
artificial intelligence and data science contents.pptxGauravCar
What is artificial intelligence? Artificial intelligence is the ability of a computer or computer-controlled robot to perform tasks that are commonly associated with the intellectual processes characteristic of humans, such as the ability to reason.
› ...
Artificial intelligence (AI) | Definitio
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
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Applications of artificial Intelligence in Mechanical Engineering.pdf
THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS OF MATERIAL EN-31 IN EDM USING COPPER ELECTRODE
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THE EFFECTS OF MACHINING PARAMETERS ON SURFACE
ROUGHNESS OF MATERIAL EN-31 IN EDM USING COPPER
ELECTRODE
Mr. Kurri Rohan Ramesh
M.E. Scholar,
Department of Mechanical Engg.
BIGCE, Solapur University, Maharashtra, India
Prof. Jagtap Shrikant Tukaram
Associate Professor,
Department of Mechanical Engg.
N.B.N. Sinhgad COE, Solapur University, Maharashtra, India
ABSTRACT
The paper represent the work done for making mathematical models for 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 explain the influences of machining parameters on
the performance characteristics in the EDM process.
KEYWORDS: EDM, EN-31, Electrode, Surface Roughness, Machining.
INTRODUCTION
In the EDM process, the surface layer of a work piece can be rapidly melted and removed by an arc of 8,000-
12,0000
C at each charge point The correct selection of manufacturing conditions 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). Over the past few years, EDM has been widely applied in the modern
metal industry for producing intricate and complex shapes. It is a capable of machining geometrically complex or
hard material components, that 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 [1]. EDM Process characteristics are Metal Removal Rate, Accuracy,
Surface finish and heat affected zone. EDM is most widely used machining process among the nontraditional
machining methods. EDM is required for manufacturing and reconditioning of press tool and forging dies and
mould for injection molding. In these processes, electricity is used as direct means to cause machining action,
moreover; the metal removal takes place in sizes of the order of microns. Here no chips are form like in
conventional processes; material is removed by melting or vaporizing small area at the surface of the work piece.
These are widely used for very hard materials. Also these are useful for producing complex and irregular shapes
and cavities, which are difficult to produce by conventional processes [1].
The benefits of EDM include:
• EDM is a non-contact process that generates no cutting forces, permitting the
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• production of small and fragile pieces
• Burr-free edges are produced
• intricate details and superior finishes are possible
• EDM machines with built-in process knowledge allow the production of
• intricate parts with minimum operator intervention
The limitations of EDM include:
• low metal removal rates compared to chip machining
• lead time is needed to produce specific, consumable electrode shapes
LITERATURE REVIEW
Abbas et al, Solomon et al and Bahari et al [2006] have been studied the recent trends in the field of Electrical
discharge machining (EDM) which is one of the earliest non-traditional machining processes.
Dhar and Purohit [1] evaluates the effect of current (c), pulse-on time (p) and air gap voltage(v) On MRR, TWR,
ROC of EDM with Al–4Cu–6Si alloy–10 wt. % SiCP composites.
Karthikeyan et .al [2] has presented the mathematical modeling of EDM with aluminium-silicon carbide
particulate composites. Mathematical equation is Y=f (V, I, T). And the effect of MRR, TWR, SR with Process
parameters taken in to consideration were the current (I), the pulse duration (T) and the percent volume fraction of
Sic (25 µ size). A three level full factorial design was choosing. Finally the significant of the models were checked
using the ANOVA.
Kuang-Yuan Kung et al (2007) [3] In this article, a material removal rate (MRR) and electrode wear ratio (EWR)
study on the powder mixed electrical discharge machining (PMEDM) of cobalt-bonded tungsten carbide (WC-Co)
has been carried out.
N.Arunkumar , H.Shareef Abdur Rawoof and R.Vivek (2012) [4] This paper presents the results of
experimental work carried out in electrical discharge machining (EDM) of EN31 (air hardened steel) using three
different tool materials namely copper, aluminium and EN24, and also the problems involved in using graphite and
brass as tool material.
Shankar Singh, S. maheswari, P. C. Pandey (2004)[5] worked on “Some investigations into the electric
discharge machining of hardened tool steel using different electrode materials” Modern EDM is capable of
machining geometrically complex or hard materials components that are precise and difficult to machine such as
heat treated tool steels, composites, super alloys, ceramics, etc.
Chiang [15] proposed mathematical models for the modeling and analysis of the effects of machining parameters
on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic which are developed using
the response surface methodology (RSM) to explain the influences of four machining parameters (the discharge
current, pulse on time, duty factor and open discharge voltage) on the performance characteristics of the material
removal rate (MRR), electrode wear ratio (EWR), and surface roughness (SR).
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Kansal .H.K et al.,(2005) [6] studied the Parametric optimization of powder mixed electrical discharge machining
by response surface methodology and observed that there is discernible improvement in surface roughness of the
work surfaces and MRR after suspending the silicon powder into the dielectric fluid of EDM.
Pecas and Henriques [2003] have found that Electrical discharge machining (EDM) is a technological process
with a large industrial implementation.
Yan Cherng Lin, Biing Hwa Yan, Yong Song Chang [7] Worked on “Machining characteristics of titanium alloy
(Ti-6Al-4V) using a combination process of EDM”.
Ashok Kumar et al. [19] machined the En-19 tool steel by using U-shaped copper electrode perform on electrical
discharge machine. Where Diameter of U-shaped electrode, Current and Pulse on time are taken as process input
parameters and material removal rate, tool wear rate, Overcut on surface of work piece are taken as output
parameters.
Kuldeep Ojha et al.[18] studied the parametric optimization for material removal rate (MRR) and tool wear rate
(TWR) on the powder mixed electrical discharge machining (PMEDM) of EN-8 steel has been carried out.
M.K. Pradhan (2008) [8] Response surface methodology was used to investigate the relationships and parametric
interactions between the three controllable variables on the material removal rate (MRR).
M.R. Shabgard, R.M.Shotorbani (2009) [9] FW4 is a newly developed hot die material widely used in Forging
Dies manufacturing. The right selection of the machining conditions is one of the most important aspects to take
into consideration in the Electrical Discharge Machining (EDM) of FW4.
OTHER IMPORTANT RESEARCHERS TO BE MENTIONED
M. M. Rahman, Md. Ashikur Rahman Khan, K. Kadirgama M. M. Noor and Rosli A. Bakar (2010) [10]
Biing Hwa Yan Che Chung Wang, worked on “the machining characteristics of Al203/6061 Al composite using
rotary electro-discharge machining with a tube electrode”
Han-Ming Chow, Biing-Hwa Yan, fuang- Yuan Huang, Jung-Cherng Hung, worked on “Study of added
powder in kerosene for the micro-slit machining of titanium alloy using electro-discharge machining”
From the various literatures that has been reviewed it is understood that much work has not been done with the
machining of EN-31, which happens to be a widely used material in the manufacturing of ball and roller bearings,
spinning tools, beading rolls, punches and dies. EN-31 is a high carbon alloy steel which achieves a high degree of
hardness with compressive strength and abrasion resistance. By its character, this type of steel has high resisting
nature against wear and can be used for components which are subjected to severe abrasion, wear or high surface
loading.
DESIGN OF EXPERIMENTS
The design of experiments technique is a very powerful tool, which permits to carry out the modeling and analysis
of the influence of process variables on the response variables. The response variable is an unknown function of the
process variables, which are known as design factors. The purpose of running experiments is to characterize
unknown relations and dependencies that exist in the observed design or process, i.e. to find out the influential
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design variables and the response to variations in the design variable values. A scientific approach to planning the
experiment must be employed if an experiment is to be performed most efficiently. The statistical design of
experiments refers to the process of planning the experiment so that appropriate data that can be analyzed by
statistical methods will be collected, resulting in valid and objective conclusions in a meaningful way. When the
problem involves data that are subject to experimental errors, statistical methodology is the only objective approach
to analysis. Sometimes, experiments are repeated with a particular set of levels for all the factors to check the
statistical validation and repeatability by the replicate data. This is called replication. To get rid of any biasness,
allocation of experimental material and the order of experimental runs are randomly selected. This is called
randomization. To arrange the experimental material into groups, or blocks, that should be more homogeneous than
the entire set of material is called blocking. So, when experiments are carried out these things should be
remembered. There are several methodologies for design of experiments. Central composite design method is used
in the present thesis.
EXPERIMENTAL SET UP
The experiments have been conducted on the Electrical Discharge Machine model ZNC of Electronica available at
large number of input parameters which can be varied in the EDM process, i.e. Discharge voltage, pulse on, pulse
off, polarity, peak current, electrode gap and type of flushing, each having its own effect on the output parameters
such as tool wear rate, material removal rate, surface finish and hardness of machined surface. Current, Discharge
voltage, pulse on and Duty factor are the parameters which were varied on the machine for experimentation. The
ranges of these parameters for the experimental work have been selected on the basis of results of previous research
work in literature review.
Figure 1 Electrical Discharge Machine Figure 2 a pictorial view of the experimental set-up for the EDM
MEASURING AND TEST EQUIPMENT USED
Surface roughness tests were conducted on all the samples produced after each of the 30 trials. Surface roughness
was measured using the Surf Test model SJ210 of Mitutoyo, Japan available in the Metrology lab of RIT, Islampur.
The equipment uses the stylus method of measurement, has profile resolution of 12 nm and measure roughness up
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to 100µm. A tracing length of 4.8 mm was used for analysis. Surface roughness of each sample was measured at
three different.
Also, MRR was measured using a weighing machine of Contech model CA-503 available in the Metrology lab of
RIT, Islampur. The details of important test equipment used in experimental study are given below:
Figure 3 Weighing Machine Figure 4 Surface Testing Machine
MACHINE TOOL
Experiments are carried out using CNC EDM (ZNC50) (Electronica) die sinking machine (shown in fig 1 Table 1
shows the specification of die sinking EDM machine.
Table 1 specification of die sinking EDM machine
EDM PROCESS PARAMETERS
1. Polarity
2. Pulse on time
Mechanism of Process Controlled erosion (melting and evaporation) through a series of electric spark
Peak Current (Ip) 0-50 (Amp)
Pulse on Time (Ton) 0-3000 (sec)
Gap Voltage (Vg) 0-100 (volt)
Spark gap 0.010 -0.500 mm
Spark frequency 200-500 kHz
Peak voltage across the gap 30-250 V
Shapes Micro holes, Narrow slots, Blind Cavities
Dielectric Fluid EDM oil, Kerosene liquid paraffin, Silicon oil, de-ionized water etc.
Specific Power
Consumption
2-10 W/mm3
/min
Metal Removal Rate (Max.) 5000 mm3
/min
Tool Material Copper, Brass, Graphite ,Ag-W Alloys, Cu-W Alloys
Limitations High Specific Energy Consumption, Non-Conducting Material can’t be machined.
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3. Pulse off time
4. Peak current
5. Discharge current
6. Pulse wave form
7. Type of dielectric medium
8. Type of flushing
9. Electrode gap
10. Electrode material
Table 2 Fixed Input Process Parameters
Sr. No. Working conditions Description
1 Electrode material Electrolytic copper
2 Electrode polarity Negative
3 Specimen material Alloy steel (EN- 31)
4 Working area (Inch2
) 2X 2
5 Dielectric fluid EDM Oil
6 Fluid pressure (kg/mm2
) 2.0
7 Working time (min) 20/15/10
RESULTS & DISCUSSIONS
Table 3 Output Surface Roughness
Run Ip Te Τ V S.R. in Ra(µ)
1 12 150 0.7 100 10.556
2 12 150 0.11 100 9.184
3 12 150 0.7 60 8.689
4 8 100 0.9 80 7.865
5 12 100 0.9 80 7.539
6 8 150 0.7 80 7.501
7 12 50 0.7 100 7.415
8 12 50 0.11 100 6.574
9 8 100 0.9 100 6.518
10 12 150 0.11 60 6.5
11 8 100 0.9 80 6.454
12 8 100 0.9 80 6.451
13 8 100 0.7 80 6.378
14 12 50 0.11 60 6.339
15 8 100 0.11 100 6.327
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16 8 100 0.9 80 6.25
17 4 150 0.7 60 6.206
18 8 100 0.9 80 6.182
19 8 50 0.7 80 6.106
20 4 150 0.11 60 6.075
21 4 150 0.7 100 6.064
22 4 100 0.9 80 6.023
23 8 100 0.9 80 5.907
24 8 100 0.9 60 5.623
25 12 50 0.7 60 5.189
26 4 50 0.11 60 4.709
27 4 50 0.7 60 4.317
28 4 50 0.7 100 4.25
29 4 50 0.11 100 4.031
30 4 150 0.11 100 4.031
CONCLUSIONS
Mathematical models SR were carried out to correlate dominant machining parameters, including the discharge
current, pulse on time, duty factor, and open discharge voltage, in the EDM process of alloy steel(EN-31). An
experimental plan of a face- centered CCD based on the RSM was employed to carry out the experimental study.
The influences of the machining parameters on the performance characteristics in the EDM process of alloy steel
(EN-31) were analyzed based on the developed mathematical model to yield the following conclusions especially
here we focused on surface roughness (S.R.) for this paper:
1. The value of SR first decreases with an increase of pulse on time before 150µs and then increases with
further increase in pulse on time. The value of SR increases with an increase of discharge current and open
discharge voltage, but, decreases with an increase of duty factor.
2. Surface Roughness value reduces with decreasing Peak Current (Ip)
3. Surface Roughness value reduces with increasing of Gap Voltage (Vg) OR simply Voltage
FUTURE SCOPE
In the present work only these variables i.e. peak current, pulse time, duty factor and open discharge voltage are
considered these responses i.e. surface roughness, electrode wear rate, and material removal rate are considered for
analysis. In future, the work may be extended for many other variables like gap voltage, Intensity, flushing
pressure, dielectric fluid, sparking time, spark gap etc. for other responses like overcut and the responses which are
covered in the present work.
Modern electrode material may be tried for minimum electrode wear and maximum material removal rate with a
good surface finish.
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The process can be optimized for the minimum electrode wear and maximum material removal rate with a good
surface finish by using modern techniques.
REFERENCES
[1] Electrical Discharge Machining by Society of manufacturing Engineers-www.sme.org
[2] Recent Advancement In Electric Discharge Machining, A Review by Amandeep Singh, Neel kanth Grover,
Rakesh sharma published in International Journal of Modern Engineering Research (IJMER) Vol.2, Issue.5, Sep-
Oct. 2012 pp-3815-3821 ISSN: 2249-6645
[3] The Use Of Response Surface Methodology For Prediction And Analysis Of Surface Roughness Of Aisi 4140
Steel By Funda Kahraman Mersin University, Tarsus Technical Education Faculty, Department of Mechanical
Education, 33400 Tarsus-Mersin, Turkey.
[4] Electrical Discharge Machining By Steve Krar.
[5] RSM: A statistical tool for process optimization, Response Surface Methodology (RSM) applied on PP filament
production brings out more interesting applications, by Srimanta Ray
[6] Analysis of Variance (ANOVA) Methods in 12th chapter by Howell, D. C. (2006) Statistical Methods for
Psychology, 6th ed. Wadsworth.
[7] ANOVA-simultaneous component analysis (ASCA): a new tool for analyzing designed metabolomics data of
bioinformatics original paper Vol. 21 no. 13 2005, pages 3043–3048 doi:10.1093/bioinformatics/bti476
[8] Shankar Singh, S. Maheswari, P. C. Pandey worked on “Some investigations into the electric discharge
machining of hardened tool steel using different electrode materials”
[9] Han-Ming Chow, Biing-Hwa Yan, fuang- Yuan Huang, Jung-Cherng Hung, worked on “Study of added powder
in kerosene for the micro-slit machining of titanium alloy using electro-discharge machining”.
[10] Kun Ling Wu, Biing Hwa Yan, Fuang Yuan Huang, Shin Chang Chen, worked on “Improvement of surface
finish on SKD steel using electro-discharge machining with aluminum and surfactant added dielectric”