A combination of Taguchi methodology and Grey Relational Analysis (GRA) inturn coupled with principal component analysis (PCA) has been proposed through this paper. This methodology is adopted in order to evaluate and estimate the effect of machining parameters over the output responses of Wire Electrical-Discharge Machining (WEDM) performed on Magnesium based metal matrix composite. In this research, an optimal combination of process parameter was expected to be finalized so as to attain a state of maximum Material Removal Rate (MRR) that too with minimal surface roughness (Ra) value. WEDM of developed composite specimens were confirmed to be of L27 orthogonal array(OA) using Taguchi’s method, based mainly on control factors namely reinforcement weight percentage (wt.%), Doping (DP %), Pulse ON time (T-ON), Pulse OFF time (T-OFF) and wire feed rate (WF). ANOVA outcome reveals that wt.% and DP% are the most influencing parameter for MRR and Ra. Multiobjective responses were normalized using GRA; further PCA was applied to evaluate the weighting values corresponding to each performance. The optimial parameter was set and the final results obtained depending on the optimal combination was found to be with a maximum MRR of 14.9 mm3/min and a minimum Ra of 2.04 μm.

WEDM Parameter Optimization for Silicon@r-GO/Magneisum Composite Using Taguchi Based GRA Coupled PCA

Electric discharge machining (EDM) is a highly promising machining process of ceramics. This research is an out of the paradigm investigation of EDM on Si3N4-TiN with Copper electrode. Ceramics are used for extrusion dies and bearing balls and they are more efficient, effective and even have longer life than conventional metal alloys. Owing to high hardness of ceramic composites, they are almost impossible to be machined by conventional machining as it entirely depends on relative hardness of tool with work piece. Whereas EDM offers easy machinability combined with exceptional surface finish. Input parameters of paramount significance such as current (I), pulse on (Pon) and off time (Poff), Dielectric pressure (DP) and gap voltage (SV) are studied using L25 orthogonal array. With help of mean effective plots the relationship of output parameters like Material removal rate (MRR), Tool wear rate (TWR), Surface roughness (Ra), Radial overcut (ROC), Taper angle (α), Circularity (CIR), Cylindricity (CYL) and Perpendicularity (PER) with the considered input parameters and their individual influence were investigated. The significant machining parameters were obtained by Analysis of variance (ANOVA) based on Grey relational analysis (GRA) and value of regression coefficient was determined for each model. The results were further evaluated by using confirmatory experiment which illustrated that spark eroding process could effectively be improved.

Modelling and experimental investigation of process parameters in EDM of Si 3 N 4 -TiN composites using GRA-RSM

Experimental investigation on single point incremental forming of IS513Cr3 using response surface method

Optimization of AA5052 in incremental sheet forming using grey relational analysis

Application of a hybrid optimization technique in a multiple sheet single point incremental forming process

This paper presents a detailed experimental investigation on single point incremental forming (SPIF) of AA5052 sheet. In order to investigate the effects of incremental forming parameters, a straight-groove test was designed using L18 orthogonal array (OA) and groves were performed along the rolling, transverse and 45° (diagonal) directions on the cold-rolled sheets. The sum of major strain and minor strain as a measure of formability and the surface roughness were measured. These multi-objective responses were normalized using grey relational analysis (GRA). Moreover, the principal component analysis (PCA) was applied to evaluate the weighting values corresponding to each performance characteristics. The variability caused by the input parameters was apportioned using analysis of variance (ANOVA). Thus, the Taguchi method (TM) based GRA coupled with PCA was specifically adopted to determine the optimal combination of forming parameters. The confirmation experiment shows an average improved formability of 56.37% and surface roughness of 93.68%.

Multi-objective optimization of single point incremental sheet forming of AA5052 using Taguchi based grey relational analysis coupled with principal component analysis

Polymer matrix composites (PMCs) generally use the inorganic and non-biodegradable materials as reinforcements. This paper presents a PMC with reinforcement of fly ash and banana fiber. The epoxy resin is used as a matrix. This paper investigates the influences of the percentage of fly ash, the percentage of banana fiber and the size of banana fiber on tensile and flexural behaviors of fly ash and banana fiber reinforced epoxy matrix composite. Taguchi’s orthogonal array is used in the design of the experiments in the sample preparations. Analysis of variance (ANOVA) is employed to find the significance of input parameters on tensile and flexural behaviors.

http://et.ippt.pan.pl/index.php/et/article/download/1086/837

Investigations on Tensile and Flexural Characteristics of Fly Ash and Banana Fiber-Reinforced Epoxy Matrix Composites

The main purpose of this research work is to study the forming limit and fracture behaviour of the AZ31 magnesium alloy, as well as to improve the formability and surface roughness of parts formed using the warm incremental sheet forming (ISF) process. For the ISF process, AZ31 Mg alloy sheets were used. Initially, Taguchi orthogonal L27 arrays were used to design experiments, and a framed multi-objective optimization problem was solved using the grey-fuzzy method. The strain-based forming fracture limit diagrams (FFLD) were plotted after a variable wall angle test. The grey-fuzzy reasoning grade (GFRG) is calculated in this study by combining grey relational analysis (GRA) and fuzzy rationale. For the AZ31 Mg alloy, the maximum GFRG value was obtained for the following forming combinations: step depth 0.3 mm, feed rate 500 mm/min, spindle speed 700 rpm, and tool diameter 10 mm. Then, ANOVA was used to determine the importance of parameters on the responses, and it was discovered that the step depth has the greatest influence (68.78%) on GFRG value, followed by the feed rate (16.56%). The fracture behaviour of the Mg alloy was studied using fractographs. Later, FE simulation was used to validate the strain value obtained from experimentation and to investigate the effect of process parameters on responses.

/pdf/experimental-investigation-and-optimization-of-az31-mg-alloy-2fpc4tf9.pdf

Experimental Investigation and Optimization of AZ31 Mg alloy during Warm Incremental Sheet Forming to Study Fracture and Forming Behaviour

In this paper, the influence of tensile and formability parameters on the forming limit diagram is reported and a model is created to predict the forming limit strains of various grades of aluminium sheet metals. Aluminium alloys of grades AA5052, AA6061 and AA8011 with a thickness 0.8 mm, 1.0 mm and 1.2 mm have been selected for the study. Experiments are conducted to construct the forming limit diagram (FLD) for the above mentioned sheet metals. Tensile tests were conducted to evaluate strain hardening index, strength coefficient, ductility, yield strength, ultimate tensile strength, normal anisotropy, planar anisotropy and strain rate sensitivity. The fractured surfaces of the specimens were viewed with a scanning electron microscope. Using Design of Experiments (DOE), regression modelling was done by taking the tensile properties and formability parameters as input variables and the forming limit strain as response. Regression equations were created to predict the limiting strain values at the tension-tension, plane strain and tension-compression strain states. The experimentally evaluated strain values were compared with the predicted strain values and the comparison shows good agreement of the values. The Taguchi method of optimization was used to find the optimum values for the input variables and using these optimum values, the optimum forming limit strains were found. It is found that the so created regression model predicts the FLD of various grades of sheet metals by which the tedious job of experimental determination of the FLD can be avoided.

/pdf/studies-on-testing-and-modelling-of-formability-in-aluminium-4hz97hzhis.pdf

Studies on Testing and Modelling of Formability in Aluminium Alloy Sheet Forming

HIGHLIGHTS Influence of Fly ash and Coir Fibre in mechanical performance of Polymer composite Polymers exhibits varying performance in tensile and flexural loading A threshold fly ash proportion has been limited to 5- 10%. Increasing fibre length shows improvement in strength whereas short fibre are good enough for modulus. 

Pandivelan Chinnaiyan

Papers

Multi-objective optimization of single point incremental sheet forming of AA5052 using Taguchi based grey relational analysis coupled with principal component analysis

Investigations on Tensile and Flexural Characteristics of Fly Ash and Banana Fiber-Reinforced Epoxy Matrix Composites

Experimental Investigation and Optimization of AZ31 Mg alloy during Warm Incremental Sheet Forming to Study Fracture and Forming Behaviour

Studies on Testing and Modelling of Formability in Aluminium Alloy Sheet Forming

Investigations on Tensile and Flexural Behaviours of Fly Ash / Coir Reinforced Polymer Matrix Composites