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![It is my privilege to present the print version of the [Volume 6 Issue 3] of our Journal of Trends in
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![TMET (2016) 1-6 © STM Journals 2016. All Rights Reserved Page 1
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Optimization of EDM Process Parameters with
Aluminium-Fly Ash Composite using Taguchi Method
Pankaj Kr Sharma1
, Shashi Prakash Dwivedi2
*, Amit Kr Sharma1
, Vijay Gautam3
1
Department of Mechanical Engineering, Raj Kumar Goel Institute of Technology, Ghaziabad,
Uttar Pradesh, India
2
Department of Mechanical Engineering, Noida Institute of Engineering Technology, Greater Noida,
Gautam Buddha Nagar, Uttar Pradesh, India
3
Department of Mechanical Engineering, Delhi Technical University, Delhi, India
Abstract
Aluminium based fly ash composites have gained huge popularity over the aluminum and its
alloy. These aluminium based composites are being widely used in various applications such
as automotive parts, machine cover, frames and ducts, etc. Fly ash addition not only makes
aluminium harder, stronger, stiffer and more wear resistant but also saves energy
consumption and helps in cutting down greenhouse emissions by utilizing almost freely
available fly ash, which is a waste of thermal power plant and problematic to dispose of. Al-
fly ash composite is electrically conductive and can be processed by Electro Discharge
Machining (EDM). Rough cutting operation in EDM is treated as a challenging one because
improvement of more than one machining performance measures viz. metal removal rate
(MRR), surface finish (SF) and tool wear are sought to obtain a precision work. Using
Taguchi’s parameter design, significant machining parameters affecting the performance
measures are identified as discharge current, pulse duration and dielectric flow. It has been
observed that a combination of factors for optimization of each performance measure is
different. In this study, the relationships between control factors and responses like MRR and
SF have been established.
Keywords: EDM, Al-fly ash composite, metal removal rate, surface finish, taguchi method
INTRODUCTION
Electro Discharge Machining (EDM) is the
thermal erosion process in which metal is
removed by a series of recurring electrical
discharges between a cutting tool acting as an
electrode and a conductive work piece, in the
presence of a dielectric fluid (Figure 1). This
discharge occurs in a voltage gap between the
electrode and work piece. Heat from the
discharge vaporizes minute particles of work
piece material, which are then washed from
the gap by the continuously flushing dielectric
fluid [1, 2]. EDM is mainly used to machine
difficult-to-machine materials and high
strength temperature resistant alloys. Work
material to be machined by EDM has to be
electrically conductive [3]. The most
important performance measures in EDM are
metal removal rate, surface finish, and tool
wear. They depend on machining parameters
like discharge current, pulse duration, pulse
frequency and dielectric flow rate.](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-10-2048.jpg)
![TMET (2016) 7-13 © STM Journals 2016. All Rights Reserved Page 7
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Experimental and Computational Analysis of Parameters
in Die-Sinking EDM Machine with AISI 316 Stainless
Steel using TOPSIS
Madhavi Pathak*, Manoj Kumar Gaur, Sharad Agrawal
Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior,
Madhya Pradesh, India
Abstract
This paper proposes an effective solution based on TOPSIS approach to determine the optimal
process parameters in die sinking electrical discharge machining. Taguchi L9 orthogonal
array is used to gather information regarding the process with less number of experimental
runs. Experiments have been conducted using three process parameters such as peak current,
gap voltage, pulse on time, with three levels are selected to optimize the multiple objectives.
AISI 316 stainless steel as a work-piece material and copper as electrode material used for
the experiments are arranged on the electrical discharge machine for the research work in
order to develop the optimal condition of the response parameters MRR and TWR.
Keywords: Response parameter (MMR, TWR), EDM, AISI 316, TOPSIS, ANOVA
INTRODUCTION
Die sinking Electrical Discharge Machining is
one of the earliest nontraditional machining
processes. EDM process is based on
thermoelectric energy in which electrical
energy is used to generate electrical spark and
material removal occurs due to thermal energy
produced by the spark. A pulse discharge
occurs in a small gap between the work-piece
and the electrode. Then fresh dielectric fluid
rushes in the gap, flushing away the debris and
quenching the surface of work-piece. The
EDM SPARK EROSION MACHINE
TOOLCRAFT A50 spark generator used for
the experiments which is having a maximum
current capacity of 50A and maximum
allowance is 0.2 mm.
Today variety of industries require materials
that are highly temperature resistant and
provide higher strength, toughness, highly
resistant to corrosion and other properties
therefore, it has become essential to have such
process that are safe and conveniently
machined the hardened materials with
accuracy hence nonconventional machines are
preferred. For machining of hardened steel, the
preferred metal cutting process is electrical
discharge machining. This process is
characterized by good material removal rate,
better dimensional accuracy and good surface
finish [1]. Basically optimization of every
machining process parameter is usually a
challenging task, because it requires
simultaneously both machining operation
experience and knowledge of mathematical
algorithms. This study presents a methodology
for evaluation and ranking by TOPSIS
approach along with Taguchi orthogonal array
[2]. The experimental analysis using the
proposed approach gave the optimized and
profitable result. The overall analysis of the
process parameters is done by statistical
ANOVA approach in MINITAB 17.0 to have
accurate results [3].
LITERATURE REVIEW
Various methodologies have been used by
researchers to understand the optimization of a
machining process. To establish a relation
between input parameters and output
parameters various approaches like empirical
relation, nonlinear regression, response surface
methodology, fuzzy-logic, VIKOR, TOPSIS,
etc. Now we have considered here TOPSIS,
simple additive weighting. Supported case
study shows the effective use of methodology
in a (EDM) nontraditional manufacturing](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-11-2048.jpg)
![TMET (2016) 14-17 © STM Journals 2016. All Rights Reserved Page 14
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Minimizing the Sand Casting Defects Using
Taguchi Method
Priyank V. Parekh1,
*, J.A. Vadher2
1
Department of Mechanical Engineering, R.K. University, Rajkot, Gujarat, India
1
Department of Mechanical Engineering, Shantilal Shah Government Engineering College,
Bhavnagar, Gujarat, India
2
Department of Mechanical Engineering, Government Engineering College, Palanpur, Gujarat, India
Abstract
The global market is becoming more and more quality conscious nowadays. This Research
work includes minimization of sand casting defects in C.I. based foundry. The survey was
carried in small-scale CI based foundry (Surat). Major defects were observed are misrun,
coldshut, blowholes, and porosity. Taguchi method is used to optimize the control parameters
like moisture, permeability, pouring time, pouring temperature. L18 orthogonal array is used
in this research work. Critical parameters are optimized using Signal to noise Ratio (S/N
Ratio).
Keywords: Casting defects, blow holes, porosity, orthogonal array, S/N ratio
INTRODUCTION
Manufacturing industry tries to maximize the
profit in the global market. In sand casting
industry the profit can be maximized by
minimization of rate of rejection of castings.
The defects can be minimized by optimization
of critical process parameters. Taguchi method
is used in the research work to optimize the
critical process parameters [1]. The relevant
data are collected from small-scale foundry
Surat.
LITERATURE REVIEW
B. Chokkalingam and S.S. Mohammad
Nazirudeen have worked on defect analysis
from different process like pattern making,
molding, core making and melting, etc. With
the use of techniques of root card analysis, the
root cause for this major defect was identified
through defect diagnostic study approach.
Finally, by taking necessary remedial actions
the total rejection rate was reduced to 4% from
28%. Conclusion of the work is the root card
analysis and systematically approach of the
work is effectively possible to eliminate and
control the casting defect [2]. Sushil Kumar
has carried out an optimization technique for
process parameters of green sand casting [3].
Table 1 is indicating the data collection of
sand casting for the month of January 2016 to
June 2016.](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-12-2048.jpg)
![TMET (2016) 18-25 © STM Journals 2016. All Rights Reserved Page 18
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Hybridizing Principle of TOPSIS with Regression Meta-
model Approach for the Optimization of CNC-WEDM
Process Parameters
Sandeep Tyagi1,
*, Manoj Kumar Gaur2
, Dinesh Kumar Kasdekar3
Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior,
Madhya Pradesh, India
Abstract
Experiment is conducted on a Computer Numerical Control wire electric discharge machine
under different conditions of process parameters. The experiment is carried out by using
Aluminum Alloy AA6061 as a work material and a Brass wire as a cutting tool in CNC-
WEDM. This paper aims to develop a combination of DOE and Entropy based TOPSIS to
solve multi response parameter optimization problems. An experimental investigation was
carried out based on DOE to analyses, the sensitivity of CNC-WEDM attributes to the
variations in process parameters such as Servo-voltage (SV), Wire-feed (WF), pulse on
time(POT), pulse off time (POF). The most desirable factor level combinations were selected
using DOE. The model developed in this study can be used as a systematic framework for
process parameter optimization in conscious manufacturing process.
Keywords: CNC-WEDM, TOPSIS, DOE
INTRODUCTION
Computer Numerically Controlled Wire
Electrical Discharge Machining (CNC-
WEDM) is one of the most popular comes
under the category of non-traditional
manufacturing process suitable for machining
very grade hard and brittle materials. The
machining processes are non-conventional in
this sense that they do not employ such
traditional tools for metal removal but they
directly use other forms of energy. The
problems of high complexity in size, shape
and higher demand for product accuracy and
surface finish can be solved through non-
traditional methods. Recent advances in the
CNC-WEDM technology made it a valuable
and viable process in the manufacturing of
critical parts such as medical, sports and
surgical, optical, instruments, aerospace and
aeronautical components including
automotive, turbine blades, Research and
development areas. WEDM has been
established to be applicable to machine
electrically conductive materials such as
stainless steels, tool steel, carbides, super
alloys, ceramic etc. in spite of their other
physical and metallurgical properties [1]. The
quality of the machined parts in WEDM is
significantly affected by control parameters
[2]. Optimal machining conditions are
accomplished by executing a detailed analysis
of all the factors affecting the process and also
the interactions between them. The major
factors influencing WEDM process are Pulse
on time, Pulse off time, Spark gap, Gap
current, etc. and physical properties of
electrode, work piece and dielectric fluid [3].
As a well-known classical MADM/MCDM
method, MCDM method has been used quite
effectively in industrial applications to
optimize and solve real-world decision
problems [4, 5] (Hwang and Yoon, 2013;
Fendel and Spronk, 1983). Methods such as
the Technique for Order Preference by
Similarity to Ideal Solution (TOPSIS),
Entropy, DOE are widely used methods.
However, these methods have their own
advantages and disadvantages [4]. In previous
MADM methods presented by researchers, a
limited number of studies have been
conducted in terms of graphical method, and
no method has been presented based on the
proposed algorithm. Among the many MADM
methods available, in our research, we have](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-13-2048.jpg)
![TMET (2016) 26-40 © STM Journals 2016. All Rights Reserved Page 26
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Innovaluation: The Skill Set for Make in India Initiative
in IOT Era
Priyavrat Thareja*, Komal Sharma, Samridhi Sharma, Jasleen Kaur, Amanpreet Singh
Faculty of Engineering and Technology, GNA University, Phagwara, Punjab, India
Abstract
This work attempts to analyze the role of new manufacturing scenario, in the IOT (Internet of
things) era, which has facilitated manufacturing automation, while simultaneously witnessing
unprecedented competitiveness. Manufacturing has been threatened in most of the world
except in China and USA, and awaits an action for a speedy recovery. One of the modes to
revival is projected through all round cost cutting. To affect cost cutting, it is envisaged that
the element of value addition be invigorated, using innovation as input and IIOT (industrial
IOT) as the tool. The latter allows manufacturers to assign each of their physical assets a
digital identity to maneuver the exact location and condition of those assets in real-time
ubiquitously throughout. The trio of Value addition, innovation, and IIOT has been paradigm
as an extension of the Joiner’s trilogy model. This set of imperatives of innovation, valuation
and IIOT, which serve for cost cutting individually and collectively, may be holistically
applied. In that holistic form these have been collated as a tool termed as Innovaluation. By
providing for the most ‘valuable’ domains fitting into Joiner’s model—grounded over
competence—Innovaluation assures achieving the most of profitability in manufacturing. This
is in line with the coveted ‘Make in India’ initiative proposed by our worthy Prime Minister,
Shri. Narendra Modi.
Keywords: Innovation, value engineering, values, manufacturing, capatence (capacity +
competence), IIOT (industrial internet of things)
INTRODUCTION
The Manufacturing Competitiveness
The world is today hot in terms of the
manufacturing competition in a scenario where
financial affluence determines not only the
political supremacy of nations but rather their
overall empowerment. Needless to say that all
weaponry, transport and energy, etc. are
aftermath of manufacturing that empowers the
nations. In spite of such affluence, there is still
a lull in manufacturing, when over the next
decade, nearly 3.5 million manufacturing jobs
will likely be needed [1] out of which 80%
manufacturers report a shortage of qualified
applicants for skilled and highly skilled
production positions. Thus, 2 million positions
are expected to remain unfilled due to the
skills gap. National Association of
Manufacturers reports that manufacturing has
the highest multiplier effect of any economic
sector through for every $1.00 spent in
manufacturing; another $1.40 is added to the
economy. Since Manufacturing makes a large
contribution in China’s GDP, the latter has
large techno-commercial supremacy vis-à-vis
the rest of world. Such success undoubtedly
rides on the back of China’s manufacturing
competency. Rightly so, this industrial tiger
[2] is being dreaded by the word in cognizance
to their nursed icon—the Dragon—which
China fondly uses to show an iconic
supremacy. Factually, China is the only
country in the world, which differs in terms of
the manufacturing contribution at say over 30
% of the GDP (c/f India at 13 %) vis-à-vis the
next higher country. This is in a scenario when
globally the overall manufacturing GDP
percentage was 23.7% of GDP in 1980 and
dropped to 17% in 2008. More so, the only
other country whose manufacturing
contribution was marginally trying to catch up
includes USA as evidenced in Figure 1, which
shows manufacturing production by country
[3] as a percent of GDP. Recently, however
China tended to outrun the competitive race,
leaving others behind at half the pace.](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-14-2048.jpg)
![TMET (2016) 41-52 © STM Journals 2016. All Rights Reserved Page 41
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Experimental Investigation on a Diesel Engine Fuelled
with Blends of Karanja Biodiesel and Diesel: Combustion
and Performance Studies
Ajay Partap Singh1,
*, Ajay Trehan2
1
Department of Mechanical Engineering, IIMT Group of Colleges, Meerut, Uttar Pradesh, India
2
Department of Mechanical Engineering, Dr. B.R. Ambedkar National Institute of Technology,
Jalandhar, Punjab, India
Abstract
With the stock of fossil fuels diminishing throughout the world and demand for energy based
comforts and mobility ever increasing, time is ripe that we strike a balance between energy
security and energy usage. Moreover having uplifted to such a sphere of engineering
excellence, reverting back to the ages of the bull carts will prove next to impossible thereby
compelling us to search for a basket of alternative fuels to derive energy to cater to our needs.
Several sources of energy, especially for driving the automotives are being developed and
tested. Biodiesel, which is a derivative of vegetable oils, is catching the attention of various
nations through its much similar properties to conventional diesel. An experimental
investigation was carried out on a small direct injection (DI) diesel engine, fuelling the engine
with 20% (B20), 50% (B20), and 100% (B100) blending of rapseed oil methyl ester with
diesel. The performance and combustion characteristics of the engine at various loads are
compared and analyzed. The results showed higher brake specific fuel consumption (BSFC)
and lower brake thermal efficiency (BTE) for the rapeseed blends. The engine indicated power
(IP) was more for the blends B20, but found to be reduced for the blend B100 when compared
to that of diesel. The engine combustion parameters such as pressure crank angle diagram,
peak pressure, time of occurrence of peak pressure, net heat-release rate, cumulative heat
release, ignition delay and combustion duration were computed. The rapeseed blends
exhibited similar combustion trend with diesel. However, the blends showed an early start of
combustion with shorter ignition delay period. The study reveals the suitability of rapeseed
blends up to B20 as fuel for a diesel engine mainly used in generating sets and the
agricultural applications in India without any significant drop in engine performance.
Keywords: Karanja oil, biodiesel, diesel, single cylinder four stroke DI engine
INTRODUCTION
Energy is primary requirement in present day
world due to increasing industrialization and
motorization. Abundant and economical
energy is life blood of modern civilization.
Energy is one of the most important building
blocks in human development, and, as such,
acts as a key factor in determining the
economical development of all countries.
Reheman et al. [1] investigated the fuel
properties of Karanja methyl ester and its
blends with diesel from 20% to 80% by
volume. In the investigation, performance and
emission of Karanja methyl ester and its
blends (B20, B40, B60 and B80) were used to
test a single cylinder, 4-stroke, DI, water
cooled diesel engine having a rated output of
7.5 KW at 3000 rpm and CR 16:1. B. Baiju et
al. [2] investigated the scope of utilization of
biodiesel developed from through the methyl
as well as ethyl alcohol route from Karanja oil
as an alternative diesel fuel. The major
problem of using neat Karanja oil as a CI
engine arises due to its very high viscosity.
Viscosity can be reduced by trans-
esterification process with alcohol and other
properties have been evaluated to be compared
with those of diesel fuel. R. A. Bakar and
Semin et al. [3] investigated the effects of fuel
injection pressure on DI diesel engine
performance. Experiments were performed on
a diesel engine with four-cylinder, two-stroke,](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-15-2048.jpg)
![TMET (2016) 53-57 © STM Journals 2016. All Rights Reserved Page 53
Trends in Mechanical Engineering & Technology
ISSN: 2231-1793(online), ISSN: 2347-9965(print)
Volume 6, Issue 3
www.stmjournals.com
Comparison of Experimental and Theoretical Results of
Tool Wear Rate in Electrical Discharge Machining
C.R. Sanghani1,
*, G.D. Acharya2
, K.D. Kothari3
1,3
Department of Mechanical Engineering, School of Engineering, R.K. University, Rajkot,
Gujarat, India
2
Department of Mechanical Engineering, Atmiya Institute of Technology and Science, Rajkot,
Gujarat, India
Abstract
Though electrical discharge machining (EDM) process is capable for complex and precise
machining of materials irrespective of their hardness, it has certain limitations like low
material removal rate (MRR), high tool wear rate (TWR), etc. which restrict its application
areas. In EDM, material removal from workpiece and tool takes place by means of sparking
between them which is a quite complex process. So, it is difficult to predict material removal
rate and tool wear rate for various process parameters. In this paper, the experimental data
available in existing literature are used to derive empirical formulas for heat distribution
factor, crater radius and depth. The tool wear rate is calculated based on these formulas and
validated with experimental results. For the selection of optimum process parameters, the
proposed theoretical model can be used in EDM process.
Keywords: EDM, TWR, experiment, empirical formula
INTRODUCTION
At the present time, electrical discharge
machining (EDM) is the widespread technique
used in industry for high-precision machining
of electrically conductive materials
irrespective of the hardness and it is widely
used for the manufacture of mould, die,
automotive, aerospace and surgical
components [1]. In this process, material
removal takes place as a result of the
generation of extremely high temperatures due
to the high-intensity discharges between tool
and workpiece that melt and evaporate the
material.
In EDM, the tool wear is a critical problem as
the change in tool shape directly affects the
final shape of the product. The contribution of
the tool cost is more than 70% to the total
operation cost in most of EDM operations. So,
during planning and designing of EDM
operations, the tool wear should be carefully
taken into consideration [2]. The amount of
electrode wear depends on various parameters
like tool-workpiece material, dielectric fluid,
flushing method, electrical parameters (pulse
on time, pulse off time, frequency of spark)
etc. [3]. Abdulkareem showed that electrode
wear can be reduced up to 27% by cooling of
electrode using liquid nitrogen [4]. Khan
found that wear along the cross-section of the
tool electrode is more compared to the same
along its length due to easier heat transfer
along the length [5].
Over last four decades, researchers are trying
to develop different models for MRR and
TWR using various techniques. Due to the
uncertainty and complexity of EDM process in
nature, so far, the material removal process in
EDM machining is still not very clear, and
hence, nobody has established a complete
mathematical model to expose the laws
governing tool wear in EDM machining.
Marafona and Chousal developed a thermal-
electrical model for sparks generated by
electrical discharge based on the Joule heating
effect [6]. Using electro-thermal concept, Yeo
et al. developed the theoretical models for the
anode and cathode in micro-EDM process [7].
Thermal analysis of workpiece was carried out
by Saedodin et al. using hyperbolic heat
conduction model [8]. Kalajahi et al.](https://image.slidesharecdn.com/trendsinmechanicalengineeringtechnologyvol6issue3-170217101041/75/Trends-in-Mechanical-Engineering-Technology-vol-6-issue-3-16-2048.jpg)
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- 4. Gargi Asha Jha Manager(Publications) PUBLICATION MANAGEMENT TEAM Internal Members External Members Bimlesh Lochab Assistant Professor Department of Chemistry School of Natural Sciences, Shiv Nadar University Gautam Buddha Nagar, Uttar Pradesh, India Dr. Rajiv Prakash Professor and Coordinator School of Materials Science and Technology Indian Institute of Technology (BHU), Varanasi Uttar Pradesh, India Dr. Rakesh Kumar Assistant Professor Department of Applied Chemistry BIT Mesra, Patna, Bihar, India Prof. S. Ramaprabhu Alternative Energy and Nanotechnology Technology Laboratory, Department of Physics Indian Institute of Technology, Chennai Tamil Nadu, India Himani Pandey Isha Chandra Senior Associate Editors Dr. Yog Raj Sood Dean (Planning and Development) Professor, Department of Electrical Engineering National Institute of Technology, Hamirpur Himachal Pradesh, India Prof. Chris Cannings Professor, School of Mathematics and Statistics University of Sheffield, Sheffield United Kingdom Dr. D. K. Vijaykumar MS, MCh (Surgical Oncology), Professor and Head Department of Surgical Oncology Amrita Institute of Medical Sciences and Research Centre Ponekkara, Cochin, Kerala, India Dr. Durgadas Naik Associate Professor (Microbiology) Management and Science University, University Drive, Seksyen13 Selangor, Malaysia Prof. José María Luna Ariza Department of Computer Sciences and Numerical Analysis Campus of Rabanales University of Córdoba, Spain Dr. Khaiser Nikam Professor, Library and Information Science Department of Library and Information Science University of Mysore Mysore, India Quaisher J Hossain Senior Editor Group Managing Editor Dr. Archana Mehrotra Managing Director CELNET, Delhi, India Meenakshi Tripathi Shivani Sharma Chairman Mr. Puneet Mehrotra Director Shambhavi Mishra Associate Editors Sugandha Mishra
- 5. Prof. Priyavrat Thareja DirectorPrincipal Rayat Institute of Engineering and Information Technology Punjab, India Dr. Baldev Raj Director, National Institute of Advanced Studies Indian Institute of Science campus Bangalore Karnataka, India Former Director Indira Gandhi Centre for Atomic Research, Kalpakkam, Tamil Nadu, India Dr. Pankaj Poddar Senior Scientist Physical and Materials Chemistry Division, National Chemical Laboratory Pune, Maharastra India Prof. D. N. Rao Professor and Head Department of Biochemistry All India Institute of Medical Sciences New Delhi, India Dr. Nandini Chatterjee Singh Additional Professor National Brain Research Centre Manesar, Gurgaon Haryana, India Dr. Ashish Runthala Lecturer, Biological Sciences Group Birla Institute of Technology and Science Pilani, Rajasthan, India Dr. Bankim Chandra Ray Professor and Ex-Head of the Department Department of Metallurgical and Materials Engineering National Institute of Technology, Rourkela Odisha, India Prof. Yuwaraj Marotrao Ghugal Professor and Head Department of Applied Mechanics Government College of Engineering Vidyanagar, Karad Maharashtra, India Dr. Hardev Singh Virk Visiting Professor, Department of Physics University of SGGS World University Fatehgarh Sahib, Punjab, India Former Director Research DAV Institute of Engineering and Technology Jallandhar, India Dr. Shrikant Balkisan Dhoot Senior Research Scientist, Reliance Industries Limited, Mumbai, India Former Head (Research and Development) Nurture Earth R&D Pvt Ltd., MIT Campus Beed Bypass Road, Aurangabad Maharashtra, India STM JOURNALS ADVISORY BOARD
- 6. Dr. Rakesh Kumar AssistantProfessor Department of Applied Chemistry Birla Institute of Technology Patna, Bihar, India Prof. Subash Chandra Mishra Professor Department of Metallurgical and Materials Engineering National Institute of Technology, Rourkela Odisha, India Dr. Shankargouda Patil Assistant Professor Department of Oral Pathology KLE Society's Institute of Dental Sciences Bangalore, Karnataka, India Prof. Sundara Ramaprabhu Professor Department of Physics Indian Institute of Technology Madras Chennai, Tamil Nadu India Dr. Baskar Kaliyamoorthy Associate Professor Department of Civil Engineering National Institute of Technology, Trichy Tiruchirappalli, Tamil Nadu, India STM JOURNALS ADVISORY BOARD
- 7. Editorial Board Prof. PriyavratThareja Director Principal, Rayat Institute of Engineering and Information Technology, Punjab India. Pramod Kumar Mishra M. N.N.I.T., Allahabad, India. Dr. N Sitaram Professor Department of Mechanical Engineering Thermal Turbomachines Laboratory Department of Mechanical Engineering IIT Madras, Chennai India. Professor K - Ramamurthi Dean, Hindustan University, Chennai, India. Dr. Raghu Vasu Prakash Indian Institute of Technology Madras Chennai 600 036, India. Prof. Shakkottai P Venkateshan Professor and Head, Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai 600036, India. Dr. Samir Saraswati Mechanical Engineering Department, MNNIT, Allahabad-211004, India. Dr. Sudarsan Nagarajan Associate Professor, Department of Mechanical Engineering National Intitute of Technology Calicut NITC Campus P.O., Calicut 673601, Kerala, India. Dr. Manoj Kumar Khurana Motilal Nehru National Institute of Technology, Allahabad-211004 India. Sudhakar Subudhi Professor, M. N.N.I.T., Allahabad, India Dr. Madhusudanan V Pillai Professor, NIT, Allahabad, India Santhakumar Mohan Professor, Mechanical Engineering, NITC, India
- 8. It is myprivilege to present the print version of the [Volume 6 Issue 3] of our Journal of Trends in Mechanical Engineering & Technology, 2016. The intension of TMET is to create an atmosphere thatstimulatesvision,researchandgrowthintheareaof MechanicalEngineering&Technology. Timely publication, honest communication, comprehensive editing and trust with authors and readers have been the hallmark of our journals. STM Journals provide a platform for scholarly research articles to be published in journals of international standards. STM journals strive to publish qualitypaperinrecordtime,makingitaleaderinserviceandbusiness offerings. The aim and scope of STM Journals is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high level learning, teaching andresearchinalltheScience,TechnologyandMedicaldomains. Finally, I express my sincere gratitude to our Editorial/ Reviewer board, Authors and publication team for their continued support and invaluable contributions and suggestions in the form of authoring writeups/reviewing and providing constructive comments for the advancement of the journals.With regards to their due continuous support and co-operation, we have been able to publish qualityResearch/Reviewsfindingsfor our customersbase. Ihopeyouwillenjoyreadingthisissue andwewelcomeyourfeedbackonanyaspectof theJournal. Dr.ArchanaMehrotra ManagingDirector STM Journals Director's Desk STM JOURNALS
- 9. 1. Optimization ofEDM Process Parameters with Aluminium-Fly Ash Composite using Taguchi method Pankaj Kr Sharma, Shashi Prakash Dwivedi, Amit Kr Sharma, Vijay Gautam 1 2. Experimental and Computational Analysis of Parameters in Die-Sinking EDM Machine with AISI 316 Stainless Steel using TOPSIS Madhavi Pathak, Manoj Kumar Gaur, Sharad Agrawal 7 3. Minimizing the Sand Casting Defects Using Taguchi Method Priyank V. Parekh, J.A. Vadher 14 4. Hybridizing Principle of TOPSIS with Regression Meta-model Approach for the Optimization of CNC-WEDM Process Parameters Sandeep Tyagi, Manoj Kumar Gaur, Dinesh Kumar Kasdekar 18 5. Innovaluation: The Skill Set for Make in India Initiative in IOT Era Priyavrat Thareja, Komal Sharma, Samridhi Sharma, Jasleen Kaur, Amanpreet Singh 26 6. Experimental Investigation on a Diesel Engine Fuelled with Blends of Karanja Biodiesel and Diesel: Combustion and Performance Studies Ajay Partap Singh, Ajay Trehan 41 7. Comparison of Experimental and Theoretical Results of Tool Wear Rate in Electrical Discharge Machining C.R. Sanghani, G.D. Acharya, K. D. Kothari 53 ContentsTrends in Mechanical Engineering & Technology
- 10. TMET (2016) 1-6© STM Journals 2016. All Rights Reserved Page 1 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Optimization of EDM Process Parameters with Aluminium-Fly Ash Composite using Taguchi Method Pankaj Kr Sharma1 , Shashi Prakash Dwivedi2 *, Amit Kr Sharma1 , Vijay Gautam3 1 Department of Mechanical Engineering, Raj Kumar Goel Institute of Technology, Ghaziabad, Uttar Pradesh, India 2 Department of Mechanical Engineering, Noida Institute of Engineering Technology, Greater Noida, Gautam Buddha Nagar, Uttar Pradesh, India 3 Department of Mechanical Engineering, Delhi Technical University, Delhi, India Abstract Aluminium based fly ash composites have gained huge popularity over the aluminum and its alloy. These aluminium based composites are being widely used in various applications such as automotive parts, machine cover, frames and ducts, etc. Fly ash addition not only makes aluminium harder, stronger, stiffer and more wear resistant but also saves energy consumption and helps in cutting down greenhouse emissions by utilizing almost freely available fly ash, which is a waste of thermal power plant and problematic to dispose of. Al- fly ash composite is electrically conductive and can be processed by Electro Discharge Machining (EDM). Rough cutting operation in EDM is treated as a challenging one because improvement of more than one machining performance measures viz. metal removal rate (MRR), surface finish (SF) and tool wear are sought to obtain a precision work. Using Taguchi’s parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration and dielectric flow. It has been observed that a combination of factors for optimization of each performance measure is different. In this study, the relationships between control factors and responses like MRR and SF have been established. Keywords: EDM, Al-fly ash composite, metal removal rate, surface finish, taguchi method INTRODUCTION Electro Discharge Machining (EDM) is the thermal erosion process in which metal is removed by a series of recurring electrical discharges between a cutting tool acting as an electrode and a conductive work piece, in the presence of a dielectric fluid (Figure 1). This discharge occurs in a voltage gap between the electrode and work piece. Heat from the discharge vaporizes minute particles of work piece material, which are then washed from the gap by the continuously flushing dielectric fluid [1, 2]. EDM is mainly used to machine difficult-to-machine materials and high strength temperature resistant alloys. Work material to be machined by EDM has to be electrically conductive [3]. The most important performance measures in EDM are metal removal rate, surface finish, and tool wear. They depend on machining parameters like discharge current, pulse duration, pulse frequency and dielectric flow rate.
- 11. TMET (2016) 7-13© STM Journals 2016. All Rights Reserved Page 7 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Experimental and Computational Analysis of Parameters in Die-Sinking EDM Machine with AISI 316 Stainless Steel using TOPSIS Madhavi Pathak*, Manoj Kumar Gaur, Sharad Agrawal Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior, Madhya Pradesh, India Abstract This paper proposes an effective solution based on TOPSIS approach to determine the optimal process parameters in die sinking electrical discharge machining. Taguchi L9 orthogonal array is used to gather information regarding the process with less number of experimental runs. Experiments have been conducted using three process parameters such as peak current, gap voltage, pulse on time, with three levels are selected to optimize the multiple objectives. AISI 316 stainless steel as a work-piece material and copper as electrode material used for the experiments are arranged on the electrical discharge machine for the research work in order to develop the optimal condition of the response parameters MRR and TWR. Keywords: Response parameter (MMR, TWR), EDM, AISI 316, TOPSIS, ANOVA INTRODUCTION Die sinking Electrical Discharge Machining is one of the earliest nontraditional machining processes. EDM process is based on thermoelectric energy in which electrical energy is used to generate electrical spark and material removal occurs due to thermal energy produced by the spark. A pulse discharge occurs in a small gap between the work-piece and the electrode. Then fresh dielectric fluid rushes in the gap, flushing away the debris and quenching the surface of work-piece. The EDM SPARK EROSION MACHINE TOOLCRAFT A50 spark generator used for the experiments which is having a maximum current capacity of 50A and maximum allowance is 0.2 mm. Today variety of industries require materials that are highly temperature resistant and provide higher strength, toughness, highly resistant to corrosion and other properties therefore, it has become essential to have such process that are safe and conveniently machined the hardened materials with accuracy hence nonconventional machines are preferred. For machining of hardened steel, the preferred metal cutting process is electrical discharge machining. This process is characterized by good material removal rate, better dimensional accuracy and good surface finish [1]. Basically optimization of every machining process parameter is usually a challenging task, because it requires simultaneously both machining operation experience and knowledge of mathematical algorithms. This study presents a methodology for evaluation and ranking by TOPSIS approach along with Taguchi orthogonal array [2]. The experimental analysis using the proposed approach gave the optimized and profitable result. The overall analysis of the process parameters is done by statistical ANOVA approach in MINITAB 17.0 to have accurate results [3]. LITERATURE REVIEW Various methodologies have been used by researchers to understand the optimization of a machining process. To establish a relation between input parameters and output parameters various approaches like empirical relation, nonlinear regression, response surface methodology, fuzzy-logic, VIKOR, TOPSIS, etc. Now we have considered here TOPSIS, simple additive weighting. Supported case study shows the effective use of methodology in a (EDM) nontraditional manufacturing
- 12. TMET (2016) 14-17© STM Journals 2016. All Rights Reserved Page 14 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Minimizing the Sand Casting Defects Using Taguchi Method Priyank V. Parekh1, *, J.A. Vadher2 1 Department of Mechanical Engineering, R.K. University, Rajkot, Gujarat, India 1 Department of Mechanical Engineering, Shantilal Shah Government Engineering College, Bhavnagar, Gujarat, India 2 Department of Mechanical Engineering, Government Engineering College, Palanpur, Gujarat, India Abstract The global market is becoming more and more quality conscious nowadays. This Research work includes minimization of sand casting defects in C.I. based foundry. The survey was carried in small-scale CI based foundry (Surat). Major defects were observed are misrun, coldshut, blowholes, and porosity. Taguchi method is used to optimize the control parameters like moisture, permeability, pouring time, pouring temperature. L18 orthogonal array is used in this research work. Critical parameters are optimized using Signal to noise Ratio (S/N Ratio). Keywords: Casting defects, blow holes, porosity, orthogonal array, S/N ratio INTRODUCTION Manufacturing industry tries to maximize the profit in the global market. In sand casting industry the profit can be maximized by minimization of rate of rejection of castings. The defects can be minimized by optimization of critical process parameters. Taguchi method is used in the research work to optimize the critical process parameters [1]. The relevant data are collected from small-scale foundry Surat. LITERATURE REVIEW B. Chokkalingam and S.S. Mohammad Nazirudeen have worked on defect analysis from different process like pattern making, molding, core making and melting, etc. With the use of techniques of root card analysis, the root cause for this major defect was identified through defect diagnostic study approach. Finally, by taking necessary remedial actions the total rejection rate was reduced to 4% from 28%. Conclusion of the work is the root card analysis and systematically approach of the work is effectively possible to eliminate and control the casting defect [2]. Sushil Kumar has carried out an optimization technique for process parameters of green sand casting [3]. Table 1 is indicating the data collection of sand casting for the month of January 2016 to June 2016.
- 13. TMET (2016) 18-25© STM Journals 2016. All Rights Reserved Page 18 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Hybridizing Principle of TOPSIS with Regression Meta- model Approach for the Optimization of CNC-WEDM Process Parameters Sandeep Tyagi1, *, Manoj Kumar Gaur2 , Dinesh Kumar Kasdekar3 Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior, Madhya Pradesh, India Abstract Experiment is conducted on a Computer Numerical Control wire electric discharge machine under different conditions of process parameters. The experiment is carried out by using Aluminum Alloy AA6061 as a work material and a Brass wire as a cutting tool in CNC- WEDM. This paper aims to develop a combination of DOE and Entropy based TOPSIS to solve multi response parameter optimization problems. An experimental investigation was carried out based on DOE to analyses, the sensitivity of CNC-WEDM attributes to the variations in process parameters such as Servo-voltage (SV), Wire-feed (WF), pulse on time(POT), pulse off time (POF). The most desirable factor level combinations were selected using DOE. The model developed in this study can be used as a systematic framework for process parameter optimization in conscious manufacturing process. Keywords: CNC-WEDM, TOPSIS, DOE INTRODUCTION Computer Numerically Controlled Wire Electrical Discharge Machining (CNC- WEDM) is one of the most popular comes under the category of non-traditional manufacturing process suitable for machining very grade hard and brittle materials. The machining processes are non-conventional in this sense that they do not employ such traditional tools for metal removal but they directly use other forms of energy. The problems of high complexity in size, shape and higher demand for product accuracy and surface finish can be solved through non- traditional methods. Recent advances in the CNC-WEDM technology made it a valuable and viable process in the manufacturing of critical parts such as medical, sports and surgical, optical, instruments, aerospace and aeronautical components including automotive, turbine blades, Research and development areas. WEDM has been established to be applicable to machine electrically conductive materials such as stainless steels, tool steel, carbides, super alloys, ceramic etc. in spite of their other physical and metallurgical properties [1]. The quality of the machined parts in WEDM is significantly affected by control parameters [2]. Optimal machining conditions are accomplished by executing a detailed analysis of all the factors affecting the process and also the interactions between them. The major factors influencing WEDM process are Pulse on time, Pulse off time, Spark gap, Gap current, etc. and physical properties of electrode, work piece and dielectric fluid [3]. As a well-known classical MADM/MCDM method, MCDM method has been used quite effectively in industrial applications to optimize and solve real-world decision problems [4, 5] (Hwang and Yoon, 2013; Fendel and Spronk, 1983). Methods such as the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), Entropy, DOE are widely used methods. However, these methods have their own advantages and disadvantages [4]. In previous MADM methods presented by researchers, a limited number of studies have been conducted in terms of graphical method, and no method has been presented based on the proposed algorithm. Among the many MADM methods available, in our research, we have
- 14. TMET (2016) 26-40© STM Journals 2016. All Rights Reserved Page 26 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Innovaluation: The Skill Set for Make in India Initiative in IOT Era Priyavrat Thareja*, Komal Sharma, Samridhi Sharma, Jasleen Kaur, Amanpreet Singh Faculty of Engineering and Technology, GNA University, Phagwara, Punjab, India Abstract This work attempts to analyze the role of new manufacturing scenario, in the IOT (Internet of things) era, which has facilitated manufacturing automation, while simultaneously witnessing unprecedented competitiveness. Manufacturing has been threatened in most of the world except in China and USA, and awaits an action for a speedy recovery. One of the modes to revival is projected through all round cost cutting. To affect cost cutting, it is envisaged that the element of value addition be invigorated, using innovation as input and IIOT (industrial IOT) as the tool. The latter allows manufacturers to assign each of their physical assets a digital identity to maneuver the exact location and condition of those assets in real-time ubiquitously throughout. The trio of Value addition, innovation, and IIOT has been paradigm as an extension of the Joiner’s trilogy model. This set of imperatives of innovation, valuation and IIOT, which serve for cost cutting individually and collectively, may be holistically applied. In that holistic form these have been collated as a tool termed as Innovaluation. By providing for the most ‘valuable’ domains fitting into Joiner’s model—grounded over competence—Innovaluation assures achieving the most of profitability in manufacturing. This is in line with the coveted ‘Make in India’ initiative proposed by our worthy Prime Minister, Shri. Narendra Modi. Keywords: Innovation, value engineering, values, manufacturing, capatence (capacity + competence), IIOT (industrial internet of things) INTRODUCTION The Manufacturing Competitiveness The world is today hot in terms of the manufacturing competition in a scenario where financial affluence determines not only the political supremacy of nations but rather their overall empowerment. Needless to say that all weaponry, transport and energy, etc. are aftermath of manufacturing that empowers the nations. In spite of such affluence, there is still a lull in manufacturing, when over the next decade, nearly 3.5 million manufacturing jobs will likely be needed [1] out of which 80% manufacturers report a shortage of qualified applicants for skilled and highly skilled production positions. Thus, 2 million positions are expected to remain unfilled due to the skills gap. National Association of Manufacturers reports that manufacturing has the highest multiplier effect of any economic sector through for every $1.00 spent in manufacturing; another $1.40 is added to the economy. Since Manufacturing makes a large contribution in China’s GDP, the latter has large techno-commercial supremacy vis-à-vis the rest of world. Such success undoubtedly rides on the back of China’s manufacturing competency. Rightly so, this industrial tiger [2] is being dreaded by the word in cognizance to their nursed icon—the Dragon—which China fondly uses to show an iconic supremacy. Factually, China is the only country in the world, which differs in terms of the manufacturing contribution at say over 30 % of the GDP (c/f India at 13 %) vis-à-vis the next higher country. This is in a scenario when globally the overall manufacturing GDP percentage was 23.7% of GDP in 1980 and dropped to 17% in 2008. More so, the only other country whose manufacturing contribution was marginally trying to catch up includes USA as evidenced in Figure 1, which shows manufacturing production by country [3] as a percent of GDP. Recently, however China tended to outrun the competitive race, leaving others behind at half the pace.
- 15. TMET (2016) 41-52© STM Journals 2016. All Rights Reserved Page 41 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Experimental Investigation on a Diesel Engine Fuelled with Blends of Karanja Biodiesel and Diesel: Combustion and Performance Studies Ajay Partap Singh1, *, Ajay Trehan2 1 Department of Mechanical Engineering, IIMT Group of Colleges, Meerut, Uttar Pradesh, India 2 Department of Mechanical Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India Abstract With the stock of fossil fuels diminishing throughout the world and demand for energy based comforts and mobility ever increasing, time is ripe that we strike a balance between energy security and energy usage. Moreover having uplifted to such a sphere of engineering excellence, reverting back to the ages of the bull carts will prove next to impossible thereby compelling us to search for a basket of alternative fuels to derive energy to cater to our needs. Several sources of energy, especially for driving the automotives are being developed and tested. Biodiesel, which is a derivative of vegetable oils, is catching the attention of various nations through its much similar properties to conventional diesel. An experimental investigation was carried out on a small direct injection (DI) diesel engine, fuelling the engine with 20% (B20), 50% (B20), and 100% (B100) blending of rapseed oil methyl ester with diesel. The performance and combustion characteristics of the engine at various loads are compared and analyzed. The results showed higher brake specific fuel consumption (BSFC) and lower brake thermal efficiency (BTE) for the rapeseed blends. The engine indicated power (IP) was more for the blends B20, but found to be reduced for the blend B100 when compared to that of diesel. The engine combustion parameters such as pressure crank angle diagram, peak pressure, time of occurrence of peak pressure, net heat-release rate, cumulative heat release, ignition delay and combustion duration were computed. The rapeseed blends exhibited similar combustion trend with diesel. However, the blends showed an early start of combustion with shorter ignition delay period. The study reveals the suitability of rapeseed blends up to B20 as fuel for a diesel engine mainly used in generating sets and the agricultural applications in India without any significant drop in engine performance. Keywords: Karanja oil, biodiesel, diesel, single cylinder four stroke DI engine INTRODUCTION Energy is primary requirement in present day world due to increasing industrialization and motorization. Abundant and economical energy is life blood of modern civilization. Energy is one of the most important building blocks in human development, and, as such, acts as a key factor in determining the economical development of all countries. Reheman et al. [1] investigated the fuel properties of Karanja methyl ester and its blends with diesel from 20% to 80% by volume. In the investigation, performance and emission of Karanja methyl ester and its blends (B20, B40, B60 and B80) were used to test a single cylinder, 4-stroke, DI, water cooled diesel engine having a rated output of 7.5 KW at 3000 rpm and CR 16:1. B. Baiju et al. [2] investigated the scope of utilization of biodiesel developed from through the methyl as well as ethyl alcohol route from Karanja oil as an alternative diesel fuel. The major problem of using neat Karanja oil as a CI engine arises due to its very high viscosity. Viscosity can be reduced by trans- esterification process with alcohol and other properties have been evaluated to be compared with those of diesel fuel. R. A. Bakar and Semin et al. [3] investigated the effects of fuel injection pressure on DI diesel engine performance. Experiments were performed on a diesel engine with four-cylinder, two-stroke,
- 16. TMET (2016) 53-57© STM Journals 2016. All Rights Reserved Page 53 Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com Comparison of Experimental and Theoretical Results of Tool Wear Rate in Electrical Discharge Machining C.R. Sanghani1, *, G.D. Acharya2 , K.D. Kothari3 1,3 Department of Mechanical Engineering, School of Engineering, R.K. University, Rajkot, Gujarat, India 2 Department of Mechanical Engineering, Atmiya Institute of Technology and Science, Rajkot, Gujarat, India Abstract Though electrical discharge machining (EDM) process is capable for complex and precise machining of materials irrespective of their hardness, it has certain limitations like low material removal rate (MRR), high tool wear rate (TWR), etc. which restrict its application areas. In EDM, material removal from workpiece and tool takes place by means of sparking between them which is a quite complex process. So, it is difficult to predict material removal rate and tool wear rate for various process parameters. In this paper, the experimental data available in existing literature are used to derive empirical formulas for heat distribution factor, crater radius and depth. The tool wear rate is calculated based on these formulas and validated with experimental results. For the selection of optimum process parameters, the proposed theoretical model can be used in EDM process. Keywords: EDM, TWR, experiment, empirical formula INTRODUCTION At the present time, electrical discharge machining (EDM) is the widespread technique used in industry for high-precision machining of electrically conductive materials irrespective of the hardness and it is widely used for the manufacture of mould, die, automotive, aerospace and surgical components [1]. In this process, material removal takes place as a result of the generation of extremely high temperatures due to the high-intensity discharges between tool and workpiece that melt and evaporate the material. In EDM, the tool wear is a critical problem as the change in tool shape directly affects the final shape of the product. The contribution of the tool cost is more than 70% to the total operation cost in most of EDM operations. So, during planning and designing of EDM operations, the tool wear should be carefully taken into consideration [2]. The amount of electrode wear depends on various parameters like tool-workpiece material, dielectric fluid, flushing method, electrical parameters (pulse on time, pulse off time, frequency of spark) etc. [3]. Abdulkareem showed that electrode wear can be reduced up to 27% by cooling of electrode using liquid nitrogen [4]. Khan found that wear along the cross-section of the tool electrode is more compared to the same along its length due to easier heat transfer along the length [5]. Over last four decades, researchers are trying to develop different models for MRR and TWR using various techniques. Due to the uncertainty and complexity of EDM process in nature, so far, the material removal process in EDM machining is still not very clear, and hence, nobody has established a complete mathematical model to expose the laws governing tool wear in EDM machining. Marafona and Chousal developed a thermal- electrical model for sparks generated by electrical discharge based on the Joule heating effect [6]. Using electro-thermal concept, Yeo et al. developed the theoretical models for the anode and cathode in micro-EDM process [7]. Thermal analysis of workpiece was carried out by Saedodin et al. using hyperbolic heat conduction model [8]. Kalajahi et al.
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