Optimizations of Edm Process Parameters for Surface Roughness Machining Die Steel Using Copper Tungsten Electrode by Adopting Taguchi Array Design
01 Oct 2012-Indian journal of science and technology (Indian Society for Education and Environment)-Vol. 5, Iss: 10, pp 3428-3432
TL;DR: In this article, the authors used the Taguchi method to formulate the experiment format, to analyze the effect of each control factors on machining characteristics, and predicts the optimal EDM control factor such as servo voltage, pulse current, pulse duration and interval time.
Abstract: In this paper, machining of hard material High Carbon High Chromium (HCHCr) die steel using Electrical Discharge Machining (EDM) with a Copper-tungsten electrode by using Tagughi methodology has been reported. The Taguchi method is used to formulate the experiment format, to analyze the effect of each control factors on machining characteristics, and predicts the optimal EDM control factor such as Servo voltage, pulse current, pulse duration and interval time. It is found that these control factors have a significant influence on machining characteristics such as material removal rate, electrode wear and Surface roughness. In order to see the impact of control factors on quality characteristic, number of experiments were conducted and. results were analyzed by Taguchi methodology and analysis of variance (standard analysis). The effect of control factors were examined for obtaining optimum surface roughness. The analysis of Taguchi method reveals that, peak current, servo voltage and pulse duration have significantly affected the surface roughness.
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TL;DR: RABAL Algorithm can be used along with Taguchi PDE to minimize the confounding effects there by accuracy of experimental results are improved and results are achieved right first time.
Abstract: It is essential to operate all manufacturing processes at optimum levels to stay competitive in the global environment. Optimum prediction in manufacturing process involves lot of experimentation as it involves time and cost. Taguchi Parameter Design (PDE) is a design where optimum prediction is achieved in lesser experimental runs subject to the condition that there is no confounding effect. Confounding effect is a drawback of Taguchi PDE due to which many Taguchi experiments fail in confirmation tests at desired confidence level. RABAL Algorithm is 12 step structured approach, which uses Orthogonality concept and linear graph for Factors and Interaction allocation and uses certain rules based on statistical concepts by which the accurate result of Taguhi parameter design experiment is ensured. Sleeve synchronizer 1&2 hard turning is a bottleneck operation in a gear manufacturing line taken for research optimized for better cycle time using Taguchi PDE and RABAL algorithm. Feed rate in first and second cut is observed as significant factors at 95% confidence level and Optimal parametric setting is identified. Accuracy of results is confirmed through confirmation tests. RABAL Algorithm can be used along with Taguchi PDE to minimize the confounding effects there by accuracy of experimental results are improved and results are achieved right first time.
4 citations
01 Jan 2014
TL;DR: In this study Taguchi approach was used, which provides the design with a systematic and efficient method for conducting experimentation and the multi objective optimization has been performed using fuzzy logic.
Abstract: In this study Taguchi approach was used, which provides the design with a systematic and efficient method for conducting experimentation . The experiments are designed using L9 orthogonal array considering three process parameter such as, Current, Pulse-On Time, Pulse-Off Time, the response of the process such as Material removal rate (MRR), Tool wear rate (TWR), Surface roughness (Ra) are considered. The experimental data used in this paper is based on the research work done by Raghuraman S et.al. The analysis of various performance criteria such as, MRR, TWR, Ra, using Taguchi method and has been done. The input-output relationship modeling has been done using Fuzzy Logic. The predicted results obtained from fuzzy logic are compared with the experimental result. Moreover the multi objective optimization has been performed using fuzzy logic.
2 citations
01 Jan 2015
TL;DR: In this paper, the effect of SiC powder mixed in the kerosene dielectric fluid was studied for powder mixed electric discharge machining (PMEDM) and the output responses were the workpiece surface roughness, material removal rate (MMR), and tool wear ratio (TWR).
Abstract: Powder mixed electric discharge machining (PMEDM) is one of the new innovations for the enhancement of capabilities of electric discharge machining process. This paper is an attempt to study the effect of SiC powder mixed in the kerosene dielectric fluid. The type of electrodes, the peak current and the pulse-on time are the main selected EDM input parameters. The workpiece and the electrodes materials are the AISI D2 die steel and copper and graphite materials, respectively. The output responses considered are the workpiece surface roughness (SR), the material removal rate (MMR) and the tool wear ratio (TWR). The experiments are planned using response surface methodology (RSM) design procedure. Empirical models are developed for SR, MRR and TWR using the analysis of variance (ANOVA) and regression models to study the effect of process parameters. The best results for the productivity of the process (MRR) obtained when using graphite electrodes at pulse current (22 A), pulse on duration (120 μs) and with silicon carbide (SiC) powder mixing in kerosene dielectrict at reaches (76.76 mm3/min). These results improved the material removal rate by (264%) with respect to the corresponding value obtained when using copper electrodes with kerosene dielectric alone. The best (TWR) results of the process obtained when using graphite electrodes at pulse current (8 A), pulse on duration (40 μs) and using the kerosene dielectric alone reduced to the level (0.1023 %). The use of graphite electrodes, the kerosene dielectric alone, the pulse current (8 A), and the pulse on duration (40 μs) yield the best (SR) with a value (2.87 μm) and improvement by (27%) with respect to the corresponding value obtained when using copper electrodes and the same parameters and machining conditions.
1 citations
01 Jan 2015
TL;DR: In this paper, the effect of EDM input parameters (type of electrode, peak current, and pulse-on time) on the surface residual stresses was studied with AISI D2 die steel in terms of an empirical equations.
Abstract: Electrical-discharge machining (EDM) technique has been increasingly adapted to new industrial applications within the field of aerospace, medical, die and mould production, precision tooling, etc. This paper concerns with studying the effect of EDM input parameters (type of electrode, peak current, and pulse-on time) on the surface residual stresses. Response surface methodology (RSM) has been used to plan the experiments. The experimental plan adopts the two level full factorial design (FFD). To verify the experimental results, the analysis of variance (ANOVA) was used and regression models are built to predict the EDM output performance characteristics, including the surface residual stresses for AISI D2 die steel in terms of an empirical equations. The results obtained when using the copper and graphite electrodes showed that the minimum tensile surface residual stresses reaches with pulse current (22 A) and pulse on duration (120 µs). The results concluded that the using of copper electrodes induced tensile residual stresses about (13.3%) lower than when using graphite electrodes.
References
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30 Sep 1996TL;DR: Quality engineering.
Abstract: Quality engineering. Analysis of quality information and quality improvement effort. Fundamentals of designing experiments. Orthogonal array experiments I. Orthogonal array experiments II. Parameter design for continuous data. Parameter design for discrete data. Alternative parameter design and other considerations. Parameter design for dynamic characteristics. Tolerance design. Response surface design and analysis.
442 citations
TL;DR: In this paper, the analysis of the Taguchi method reveals that the electrical group more significantly affects the machining characteristics than the non-electrical group, and also derived a semi-empirical equation that contains all machining properties.
Abstract: 1. Electrical parameters, e.g. polarity, peak current, pulse duration, and powder supply voltage.
2. Non-electrical parameters, e.g. circumferential speed of electrode, reciprocating speed. The analysis of the Taguchi method reveals that, in general, the electrical group more significantly affects the machining characteristics than the non-electrical group. Also derived herein are semi-empirical equation that contain all of the machining characteristics. Experimental results are presented to illustrate the proposed approach.
102 citations
TL;DR: In this paper, rough and finish machining conditions were tested using copper and tungsten-copper as materials for the electrodes, and appropriate parameters settings for EDM of the investigated alloy were suggested.
Abstract: High-strength copper alloys are used as materials for injection molding tools or as cores and inserts in steel molds because of their high thermal conductivity, corrosion and wear resistance. Unfortunately, there is little technological knowledge on the electrical discharge machining (EDM) of copper-beryllium ASTM C17200 alloy. In this work, rough and finish machining conditions were tested using copper and tungsten-copper as materials for the electrodes. Cross-sectional micrographic and hardness examinations as well as surface roughness measurements were also carried out on workpieces after machining in order to study the thermally affected zones. Appropriate parameters settings for EDM of the investigated alloy are suggested.
57 citations