Parameter optimization of electrical discharge machining process by using Taguchi approach (original) (raw)
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Proceedings of the National Conference on Trends and Advances in Mechanical Engineering,, 2017
Optimization is a process or a technique to make something perfect or effective as much as possible. Optimization is one of the best methodology used in manufacturing and production sectors to attain the optimal manufacturing conditions at lower cost with the optimal results. Electric discharge machining is the non-traditional machining process. Basically, EDM is used for the hard metals or those materials which are difficult to machine by some other traditional processes. The electric discharge machining process based upon the thermo electric energy between the work piece and the electrode. In this the material removal is occurred electro thermally by a series of successive discharges that are between the electrode and work piece. Aim of this paper was to investigate the optimal set of process parameters such as Voltage, Current and Pulse on time in the electric discharge machining to identify the variations in the three characteristics such as Material removal rate (MRR), Tool wear rate (TWR), and Surface roughness (Ra) on the work piece Mild Steel IS 2026 and the electrode is Copper. Machining process is done to achieve results like higher material removal rate, better surface finish and lesser tool wear rate. Taguchi method and ANOVA technique is used to get the optimized result. Graphs and response table are used to find the optimal levels of the parameters in the Electric discharge machining. The result revealed that the current, voltage & pulse on time have a great influence on the MRR,TWR and surface roughness.
Optimization of Process Parameters in Electro- Discharge Machining using Taguchi Method
Electric discharge machining is the essential non-traditional machining process. Basically the EDM is mainly used for the hard metals or those materials which are difficult to machine by some other traditional processes. The electric discharge machining process based upon the thermo electric energy between the workpiece and electrode. In this the material removal is occurred electro thermally by a series of successive discharges that are between the electrode and workpiece. With the help of optimization techniques we can attain the best manufacturing environment, which is an essential need for industries to improve the manufacturing qualities of products at the lower cost. This research paper aims to investigate the optimal set of process parameters such as pulse on time, voltage, current in the Electric discharge machining process to achieve results like higher material removal rate, better surface finish and lesser tool wear rate. The experiment is done on the Mild steel AISI18 work piece and the electrode taken is of copper. Taguchi method is used to get the optimized result. Graphs and response table are used to find the optimal levels of the parameters in the Electric discharge machining. The result revealed that the current, voltage & pulse on time have a great influence on the MRR, TWR and surface roughness. At higher value of Voltage, lower value of current & lower value of pulse on time we get the best optimal values of MRR, Ra & TWR. Keywords: Electric discharge machining, AISI18 steel work-piece, copper electrode, Current, Voltage, Pulse on time, Taguchi L9 orthogonal array, Miinitab-17, S/N ratio, Surface Roughness (Ra), Material Removal Rate(MRR), Tool Wear Rate(TWR) ________________________________________________________________________________________________________
This research outlines the Taguchi"s Parameters Design Approach which is applied to optimize machining parameters of dimensional accuracy in wire cut electric discharge machining (WEDM). Analysis of variance (ANOVA) is used to study the effect of process parameters on machining process. This procedure eliminates the need for repeated experiments, save time and conserves the material as opposed by the conventional procedure. The machining parameters investigated are pulse on time(Ton) , pulse off time (Toff),Spark gap voltage(SV) and gap current(IP). A series of experiments are conducted using EDM to related the machining parameters and dimensional accuracy. An orthogonal array has been used to conduct the experiments and raw data and signal to noise ratio are employed to analyse the influence of these parameters on dimensional accuracy. The methodology could be useful in predicting dimensional accuracy parameters as a function of machining parameters and specimen parameters. The main objective is to find out the important factors and combination of factors influencing the machining process to achieve the best material removal rate (MRR). It has been observed that effect of combination of factor for each parameter measure is difficult. In this study MINITAB 15 is used to: find out the effect of each parameter on response characteristic and to predict the optimum setting of control parameters. In this study EN24 Steel is used for the experimental work as work piece.
Optimization is a process or a technique to make something perfect or effective as much as possible. Optimization is one of the best methodology used in manufacturing and production sectors to attain the optimal manufacturing conditions at lower cost with the optimal results. Electric discharge machining is the non-traditional machining process. Basically, EDM is used for the hard metals or those materials which are difficult to machine by some other traditional processes. The electric discharge machining process based upon the thermo electric energy between the work piece and the electrode. In this the material removal is occurred electro thermally by a series of successive discharges that are between the electrode and work piece. Aim of this paper was to investigate the optimal set of process parameters such as Voltage, Current and Pulse on time in the electric discharge machining to identify the variations in the three characteristics such as Material removal rate (MRR), Tool wear rate (TWR), and Surface roughness (Ra) on the work piece Mild Steel IS 2026 and the electrode is Copper. Machining process is done to achieve results like higher material removal rate, better surface finish and lesser tool wear rate. Taguchi method and ANOVA technique is used to get the optimized result. Graphs and response table are used to find the optimal levels of the parameters in the Electric discharge machining. The result revealed that the current, voltage & pulse on time have a great influence on the MRR,TWR and surface roughness. KEYWORDS: Electric discharge machining, Mild Steel IS 2026 work-piece, copper electrode, Current, Voltage, Pulse on time, Taguchi L9 orthogonal array, Miinitab-17, ANOVA, S/N ratio, Surface Roughness (Ra), Material Removal Rate(MRR), Tool Wear Rate(TWR). .
OPTIMIZATION OF PROCESS PARAMETERS IN ELECTRICAL DISCHARGE MACHINING PROCESS BY USING TAGUCHI METHOD
The objective of this research study is to investigate the optimal process parameters of Electric Discharge Machining on RENE80 nickel super alloy material with aluminum as a tool electrode. The effect of various process parameters on machining performance is investigated in this study. The input parameters considered are current, pulse on time and pulse off time are used for experimental work and their effect on Material Removal Rate, Tool Wear Rate and Surface Roughness. The Taguchi method is used to formulate the experimental layout, ANOVA method is used to analysis the effect of input process parameters on the machining characteristics and find the optimal process parameters of Electric Discharge Machining. The results of the present work reveal that proper selection of input parameters will play a significant role in Electric Discharge Machining.
Indian Journal of Science and Technology, 2016
Objectives: To find the important parameters that affects the performance output (i.e.) to boost the Material Removal Rate (MRR) of the workpiece. Methods: Electro-Discharge Machining (EDM) is a thermal based machining process which is used to remove 'hard to cut materials' with complex shapes. The principle with the EDM or spark eroding machining is that the unwanted materials are removed with the repeated current discharges between cathode and the anode, separated by a dielectric fluid and is subjected to an electric voltage. Findings: This paper investigates in optimizing the process variables of EDM by employing a traditional technique. The parameters chosen for optimization are pulse on time, pulse off time followed by the current and L 9 Orthogonal Array (OA) has been selected to examine the impact of the process variables on the performance i.e. on the material removal rate. The experimental trials have been done on AISI D2 die steel with positive polarity and brass has been chosen as an electrode material. Applications: Mainly, the EDM are employed to machine difficult to cut materials like nickel base super alloys, titanium etc.
This work reports about the Taguchi approach for parametric optimization for WEDM parameters like peak current, pulse on time and pulse off time for material removal rate, kerf width and surface roughness. Experiments were designed and planned using Taguchi L-9 orthogonal array. Signal-to-Noise ratios have been calculated from experimental observations. The significant parameters that critically influence the machining characteristics were examined by ANOVA. A mathematical model is developed for predicting the response quality using regression analysis. Further experiments were conducted with optimized parameters to authenticate the usefulness of proposed investigation. The confirmation experiment result shows that the model suggested by Taguchi's method is suitable for improving selected responses.
Optimization of Process Parameters in Electric Discharge Machining Process
Electro Discharge Machining (EDM) is an extremely prominent machining process among newly developed non-traditional machining techniques for “difficult to machine” conducting materials such as heat treated tool steels, composites, super alloys, ceramics, hastelloys, nitralloy, nemonic alloys, carbides, heat resistant steels etc. In EDM, the material removal of the electrode is achieved through high frequency sparks between the tool and the work-piece immersed into the dielectric. The Material Removal Rate (MRR) is the important performance attributes of EDM process. The machining parameters that achieve the highest MRR strongly depend on the size of the machining surface i.e. the engaged electrode and work-piece surface. With upcoming worldwide applications of Titanium grade-2, machining has become an important issue which needs to be investigated in detail. A well-designed experimental were conducted with L18 Orthogonal Array (OA) based on the design of experiment (DOE) with input factors like Peak Current (Ip), Pulse Time On (Ton), Duty Cycle (TAU) and Voltage Gap (V) was considered for investigation. The effect of the machining parameters on the responses such as MRR was investigated. In this research work, Regression analysis was used to find out the optimal levels of the parameters. Keywords: Electric Discharge Machining (EDM), Titanium grade-2, Design of Experiment (DOE), Regression Analysis, Material Removal Rate.
OPTIMIZATION OF ELECTRIC DISCHARGE MACHINING EXPERIMENTAL PARAMETERS BY TAGUCHI ANALYSIS
ijetrm journal, 2022
For conventional machining, a tool that is more abrasive than the work piece is required. In the conventional machining technique, also known as conventional machining, the tool entered the work component to a certain depth. In a traditional machining process, the form of the item is achieved by the relative motion between the tool and the work piece. While in non-traditional or non-conventional machining, there is no contact between the work piece and the tool. In this thesis, we use Taguchi's based design of experiments methods to improve the material removal rate (MRR) and surface roughness (SR). The use of an Electric Discharging Machine The most critical parameter in MRR is the discharge current (I), due to the fact that its contribution is greater than that of any other parameter. MRR can be enhanced by adjusting the discharge current (I), according to the results of the analysis.
International Journal of Research, 2017
EDM has become an significant and cost-effective method of machining really tough and brittle electrically conductive materials. It is widely used in the process of making molds and dies and sections of compound geometry and intricate shapes. The work piece material selected in this experiment is SAE-8620 alloy steel taking into account its wide usage in industrial applications. In today’s world SAE-8620 alloy steel contribute to almost half of the world’s production and consumption for industrial purposes. The input variable parameters are current, pulse on time and duty cycle. With the help of MINITAB software an orthogonal array of input variables was created using the design of experiments (DOE). The effect of the variable parameters mentioned above upon machining characteristics such as material removal rate (MRR), tool wear rate (TWR) is calculated and investigated. The tool material is copper, brass.The results reveal that the primary factor affecting the MRR is peak current ...