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Showing papers on "Electrical discharge machining published in 2018"


Journal ArticleDOI
TL;DR: In this paper, the experimental and theoretical studies on EDM that aimed to improve the process performance, including material removal rate, surface quality, and tool wear rate, among others.
Abstract: Electric discharge machining (EDM) is one of the leading edge machining processes successfully used to machine hard-to-cut materials in wide range of industrial applications. It is a non-conventional material removal process that can machine a complex shapes and geometries with high accuracy. The principle of the EDM technique is to use thermoelectric energy to erode conductive components by rapidly recurring sparks between the non-contacted electrode and workpiece. To improve EDM performance, the machine’s operating parameters need to be optimized. Studies related to the EDM have shown that the appropriate selection of the process, material, and operating parameters had considerably improved the process performance. This paper made a comprehensive review about the research studies on the EDM of different grades of titanium and its alloys. This review presents the experimental and theoretical studies on EDM that aimed to improve the process performance, including material removal rate, surface quality, and tool wear rate, among others. This paper also examines evaluation models and techniques used to determine the EDM process conditions. Moreover, the paper discusses the recent developments in EDM and outlines the progression for future research.

96 citations


Journal ArticleDOI
TL;DR: This paper attempts to provide an insight into the state of the art of the EDM process, types of ceramics materials and their applications, as well as the machining techniques involved.
Abstract: Conventional machining techniques of ceramics such as milling, drilling, and turning experience high cutting forces as well as extensive tool wear. Nevertheless, non-contact processes such as laser machining and electro-discharge machining (EDM) remain suitable options for machining ceramics materials, which are considered as extremely brittle and hard-to-machine. Considering the importance of ceramic machining, this paper attempts to provide an insight into the state of the art of the EDM process, types of ceramics materials and their applications, as well as the machining techniques involved. This study also presents a concise literature review of experimental and theoretical research studies conducted on the EDM of ceramics. Finally, a section summarizing the major challenges, proposed solutions, and suggestions for future research directions has been included at the end of the paper.

87 citations


Journal ArticleDOI
TL;DR: In this paper, the surface and subsurface quality generated by different machining processes were quantitatively evaluated from the aspects of surface morphology and roughness, micro-hardness, residual stress and sub-surface quality.

86 citations


Journal ArticleDOI
TL;DR: In this paper, electrical discharge machining (EDM) process is used for machining conductive and difficult-to-cut materials, but low material removal rate (MRR) and poor surface quality are major limitations.
Abstract: Electrical discharge machining (EDM) process is popular for machining conductive and difficult-to-cut materials, but low material removal rate (MRR) and poor surface quality are major limitations o...

80 citations


Journal ArticleDOI
TL;DR: In this article, the impact of SiC powder concentration on surface topography, particles deposition and subsurface structures in powder mixed electrical discharge machining (PMEDM) of Ti-6Al-4V-ELI work material was examined.

74 citations


Journal ArticleDOI
TL;DR: In this paper, the impact of WEDM process parameters, such as pulse on time, pulse off time, peak current and servo voltage in machining of Nimonic-263 alloys, is examined.

70 citations


Journal ArticleDOI
TL;DR: In this article, the authors present an innovative simultaneous flushing and vacuum-assisted debris removal system, which facilitates better debris removal for deep-hole electrical discharge machining (EDM) drilling, which is often used for drilling holes in difficult-to-cut materials such as Nickel-based super alloys.

69 citations


Journal ArticleDOI
TL;DR: In this paper, the analysis and optimization of µEDM by using a multi-objective genetic algorithm (MOGA-II) is performed by drilling micro-holes using a tabletop electrical discharge machine.

66 citations


Journal ArticleDOI
TL;DR: In this paper, the optimal setting of machining parameters (gap voltage, pulse on time, pulse off time, discharge current, and wire feed) for the best quality of machined surface and the narrowest width of kerf for precision machining was found.

65 citations


Journal ArticleDOI
TL;DR: In this article, an Elman-based Layer Recurrent Neural Network (LRNN) was used to predict the accuracy of components produced by WEMD by using an ELMAN-based layer recurrent neural network, and the results reveal that the average deviation between network predictions and actual components is below 6μm.
Abstract: For many industrial sectors, high-added value components are related to high accuracy manufacturing technologies. Wire Electrical Discharge Machining (WEDM) is an advanced non-conventional machining method commonly used in the production of precision components in extremely hard materials. The precision of the process depends largely on the deformation of the wire tool. Whilst theoretical models allow a scientific understanding of the causes of a lack of accuracy, they still lack the level of precision required to predict actual deviations in industrial products. In this work, we propose a way to predict the accuracy of components produced by WEMD by using an Elman-based Layer Recurrent Neural Network (LRNN). The results reveal that the average deviation between network predictions and actual components is below 6μm, which implies extremely good performance of the net. In a further step, an algorithm was proposed for designing wire paths of variable radius, so that the deviations in the machined parts can be corrected via software. By combining the predictions of the developed LRNN with the Simulated Annealing (SA) optimization technique, wire paths of variable radius can be designed, so that radial deviations due to wire deformations can be minimized. The results show that the new proposal is very efficient in those situations in which wire deformation is greatest. In other words, when the part radius is low and part height is large, the stiffness of the wire is reduced and the error of the part sharply increases. In these cases, the average deviation was reduced by as much as 80%, and the Coefficient of Variation (CV) was decreased by 43%. The solution can be readily implemented on any existing WEDM machine.

61 citations


Journal ArticleDOI
TL;DR: In this paper, a machined Ti-6Al-4V ELI (Grade 23) was machined with EDM machining process taking pulse on time, voltage and current as the process parameters.

Journal ArticleDOI
TL;DR: In this article, a review of the trends and developments of the machining of biocompatible materials using conventional (milling, turning and drilling) and non-conventional or advanced (abrasive water jet machining (AWJM), ultrasonic machining, USM, ion beam machining(USM), LBM, EBM, and electrical discharge machining) is presented and discussed.
Abstract: The need for more effective and efficient manufacturing processes to transform the biocompatible materials into high standard artificial human body components (implants) is rapidly growing. Machining of biocompatible materials as one of the key processes in manufacturing of implants need to be improved due to the significant effects of machined surface quality to the compatibility and osseointegration with human organs such as tissues, bones, and environment of the human body. The challenges of machining biocompatible materials due to their applications as bio-implants in the human body and the nature of materials properties and microstructures have been explored and solved by various researchers. This article reviews the trends and developments of the machining of biocompatible materials. A range of possible machining technologies and strategies on various biocompatible materials using conventional (milling, turning and drilling) and non-conventional or advanced (abrasive water jet machining (AWJM), ultrasonic machining (USM), ion beam machining (IBM), laser beam machining (LBM), electrical discharge machining (EDM), and electron beam machining (EBM)) are presented and discussed. This review also examines the emerging new technologies such as additives manufacturing and hybrid processes as potential solutions and future research trends in order to fulfill the high standard requirements for a wider range of applications of the biomaterials.

Journal ArticleDOI
TL;DR: In this paper, the significance of machining parameters such as pulse-on time, servo voltage, pulse-off time, peak current, wire feed rate and cable tension on performance features such as surface roughness (SR), overcut and metal removal rate (MRR).
Abstract: In this research, Wire Electrical Discharge Machining (WEDM) of Nimonic-75 alloy is presented to explore the significance of machining parameters such as pulse-on time, servo voltage, pulse-off time, peak current, wire feed rate and cable tension on performance features such as surface roughness (SR), overcut and metal removal rate (MRR). Experiments are performed according to Taguchi’s L27 orthogonal collection. Principal component analysis is utilized for the optimization of machining parameters. The optimal settings of the machining variables obtained are pulse-on time 110 µs, pulse-off time 51 µs, servo voltage 40 volts, peak current 230 Amp., wire feed rate 5 m/min and cable tension 8 gram. Results of Analysis of Variance (ANOVA) reveal that pulse-on time (contributing 52.90%) is the major influencing factor affecting the performance characteristics. Results of the confirmation experiments indicate that the optimal machining parameters improved the value of composite primary component (CPC) from 1.2013 to 1.2443 for the multiple responses. Scanning Electron Microscopic (SEM) analysis is carried out to examine the microstructure of the machined surfaces.

Journal ArticleDOI
TL;DR: In this paper, the authors used the Taguchi-TOPSIS method to optimize material removal rate (MRR), surface roughness (SR), and the micro-hardness of a machined surface (HV) in electrical discharge machining of die steels in dielectric fluid with mixed powder.
Abstract: Mixing powder into dielectric fluid in electrical discharge machining (PMEDM) is a very interesting technological solution in current research. This method has the highest efficiency in simultaneously improving the productivity and quality of a machined surface. In this study, material removal rate (MRR), surface roughness (SR), and the micro-hardness of a machined surface (HV) in electrical discharge machining of die steels in dielectric fluid with mixed powder were optimized simultaneously using the Taguchi–TOPSIS method. The process parameters used in the study included workpiece materials (SKD61, SKD11, SKT4), electrode materials (copper, graphite), electrode polarity, pulse-on time, pulse-off time, current, and titanium powder concentration. Some interaction pairs among the process parameters were also used to evaluate the effect on the optimal results. The results showed that MRR and HV increased and SR decreased when Ti powder was mixed into the dielectric fluid in EDM. Factors such as powder concentration, electrode material, electrode polarity, and pulse-off time were found to be significant in the optimal indicator (C*) and the S/N ratio of C*. Powder concentration was also found to be the most significant factor; its contribution to C* was 50.90%, and S/N ratio of C* was 51.46%. The interactions of the powder concentration and certain process parameters for C* were found to be largest. The optimum quality characteristics were MRR = 38.79 mm3/min, SR = 2.71 μm, and HV = 771 HV. The optimal parameters were verified by experiment, and its accuracy was good (max error ≈13.38%). The finished machined surface under optimum conditions was also analyzed. The machined surface quality under optimum conditions was good. In addition, the results of the study showed the TOPSIS limitations of TOPSIS in a multi-criteria optimization problem.

Journal ArticleDOI
TL;DR: In this paper, the performance of these specimens, in the as-build condition, is showed to be largely poor because of surface integrity defects and unfavourable microstructure formation.

Journal ArticleDOI
TL;DR: In this paper, a comparative study has been carried out on electro discharge machining (EDM) of titanium grade 6 alloy using different type of electrodes viz. copper, brass and zinc.

Journal ArticleDOI
TL;DR: The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap.
Abstract: When machining a small hole with high aspect ratio in EDM, it is hard for the flushing liquid entering the bottom gap and the debris could hardly be removed, which results in the accumulation of debris and affects the machining efficiency and machining accuracy. The assisted ultrasonic vibration can improve the removal of debris in the gap. Based on dynamics simulation software, Fluent, a three-dimensional (3D) model of debris movement in the gap flow field of EDM small hole machining assisted with side flushing and ultrasonic vibration is established in this paper. The laws of different amplitudes and frequencies and different aspect ratios on debris distribution and movement are quantitatively analyzed. The motion height of debris was observed under different conditions. The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap. When compared to traditional small hole machining in EDM, the debris in the machining gap were greatly reduced, which ensures the stability of the machining process and improves the machining efficiency.

Journal ArticleDOI
TL;DR: In this paper, the authors focused on the improvement in response characteristics by eliminating the occurrence of arcing and short circuiting in micro electric discharge drilling (EDD) by modifying the tool electrode geometry.
Abstract: Micro electric discharge machining (μ-EDM) is a widely used process for machining of difficult to machine materials. The occurrence of arcing and short circuiting in micro electric discharge drilling (EDD) is a common problem which limits the aspect ratio achieved during the process. The present study is focused on the improvement in response characteristics by eliminating the occurrence of arcing and short circuiting. These problems can be addressed by modifying the tool electrode geometry. Although, EDD using shaped tool electrodes improve response characteristics as proven by the previous studies, but time spent in electrode fabrication must also be considered as it affects the overall productivity. Considering the literature related to EDD using shaped tool electrodes, the proposed electrode has been found to have minimum electrode fabrication time i.e. 9 min for an electrode length of 3.2 mm. Therefore, the proposed electrode is capable of producing holes of high aspect ratio with minimum electrode fabrication time. The proposed electrode was also found to be effective in eliminating the accumulation of debris in the machining zone. Moreover, the need of flushing during the process has been totally eliminated making it a self-flushing electrode. The mechanism of removal of debris is well explained based on the images captured using a high speed camera. The performance of the proposed electrode was evaluated with respect to response characteristics such as material removal rate, tool wear rate, aspect ratio, taper angle and corner radius of the drilled hole. A substantial increase of 300% in aspect ratio was recorded using the designed electrode as compared to the solid cylindrical electrode for the hole diameter of 0.8 mm.

Journal ArticleDOI
TL;DR: In this article, a detailed exploration on real-time wire electric discharge machining (WEDM) experiments and grey relational analysis (GRA)-based multi-criteria optimization of material and machining characteristics for lowered surface roughness (Ra) and improvised material removal rate (MRR) of the newly developed magnesium/boron nitride/cathode ray tube (Mg/BN/CRT) hybrid metal matrix composites (MMC).
Abstract: The current work presents a detailed exploration on real-time wire electric discharge machining (WEDM) experiments and grey relational analysis (GRA)–based multi-criteria optimization of material and machining characteristics for lowered surface roughness (Ra) and improvised material removal rate (MRR) of the newly developed magnesium/boron nitride/cathode ray tube (Mg/BN/CRT) hybrid metal matrix composites (MMCs). The composites were fabricated through powder metallurgy (PM) route by reinforcing silica-rich E-waste CRT panel glass powder crushed for different particle sizes (10, 30, and 50 µm) at various weight percentages (5%, 10%, and 15%) and with 2% boron nitride (BN). Taguchi-based orthogonal array procedure was utilized to formulate the experimental plan for WEDM considering reinforcement level and size, pulse on time (Pon), pulse off time (Poff), and wire feed (Wf) as the input process parameters. ANOVA results reveal that Pon and wt% of reinforcement has more effect on Ra and MRR than any...

Journal ArticleDOI
TL;DR: Inconel 718 was machined using copper-tungsten electrode with tool rotation about 300rpm as mentioned in this paper, and a mathematical model was developed to correlate the influences of these variables such as Peak current (Ip), Sparking gap (V), Pulse on time, (Ton), duty cycle and slurry concentration on MRR.
Abstract: The rotary tool is a recent innovation of PMEDM. Aluminium oxide (Al2O3) powder with a particle concentration of 0.5–1.5 gm/l was added into the dielectric to study improved machining performance. Inconel 718 was machined using copper–tungsten electrode with tool rotation about 300 rpm. Experiments were designed using Taguchi’s three-level L18 orthogonal array. A mathematical model is developed to correlate the influences of these variables such as Peak current (Ip), Sparking gap (V), Pulse on time, (Ton), duty cycle and slurry concentration on MRR. A mean effect plots are generated to develop correlation between the influences of these variables such as Material Removal Rate, Tool Wear Rate, Surface Roughness and Heat affected zone. Recast layer affect means by Scanning Electron Microscopy (SEM).

Journal ArticleDOI
13 Dec 2018
TL;DR: In this article, the optimal parameters for machining of Ti-6Al-4V using EDM with graphite electrode were investigated, and a technique of modifying surface properties and enhancing machining rate using electrical discharge machining (EDM) was developed.
Abstract: The present study investigates optimal parameters for machining of Ti-6Al-4V using EDM with graphite electrode. Herein, another technique of modifying surface properties and enhancing machining rate using electrical discharge machining (EDM) was developed. In the present study, design of experiment (D.O.E) was developed using the Taguchi’s orthogonal array to examine the effect of the input machining factors on the machining characteristics, and to forecast the optimized EDM parameters in terms of peak current, pulse-on time, pulse-off time and applied gap voltage. Each experiment was performed to obtain a hole of 1mm depth on the workpiece. From the results, it is found that the discharge current has significant influence on material removal rate (MRR) and surface roughness (SR) followed by other selected parameters, i.e. pulse-on time, pulse-off time. The MRR augmented steeply with the current and was recorded as maximum at 4 Amps. In-vitro bioactivity test was conducted in the simulated body fluid to examine bioactivity confirming a significant apatite growth on the surface treated with ED sparks. The surface and chemical alteration were analyzed by using Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD) along with the identification of the substantially enhanced morphology for clinical success.

Journal ArticleDOI
TL;DR: In this article, the mechanism of wire electrode rupture during electrical discharge machining (EDM) of Ti-6Al-4V alloy has been investigated in the presence of electrolyte flushing pressure, wire tension and pulse-on-time.

Journal ArticleDOI
TL;DR: In this article, a high-speed camera with a laser bandpass filter added in front of the camera lens to filter out the plasma was used to directly observe the discharge process of CFRPs without the interfere of the plasma.
Abstract: Electrical discharge machining (EDM) has been proved to be a feasible way to machine the carbon fiber reinforced polymers (CFRPs); therefore, understanding the material removal mechanism of CFRPs by EDM is significantly important for optimizing the machining process and improving the machining surface quality. However, very few researches to reveal the above mechanism exist. To address this issue, this paper investigated on the material removal mechanism of CFRPs by EDM from thermal, mechanical and chemical respects. The heat conduction analysis (thermal aspect) was carried out to study the temperature distribution during the discharge process of CFRPs, which shows that CFRPs could be removed through the thermal decomposition and vaporization of the epoxy resin and the sublimation of the carbon fibers under ultra-high temperature caused by the plasma heat and Joule heat. On the other hand, a high-speed camera with a laser bandpass filter added in front of the camera lens to filter out the plasma was used to directly observe the discharge process of CFRPs without the interfere of the plasma, which shows that massive high-speed jets were emitted into the gap in the discharge process, producing the jetting force (mechanical aspect). Specifically, when the discharge occurred on the parallel surface of CFRPs, the carbon fibers were crashed by the jets whose motion direction was vertical to the arrangement direction of the carbon fibers, then removed by the jetting force. However, when the discharge occurred on the vertical surface, the jetting force was not the main way of the material removal of CFRPs. Moreover, the experiments were carried out in both deionized water and EDM oil to investigate the chemical removal mechanism. It was found that in the discharge of CFRPs with the oxygen environment, the oxidation reaction could not only generate extra heat but also enhance the jetting force, thus, reaching a much higher material removal rate.

Journal ArticleDOI
01 May 2018-Silicon
TL;DR: In this article, a hybrid approach has been used to optimize the material removal rate (MRR) as well as surface roughness (SR) and significant control parameters have been identified using ANOVA.
Abstract: Wire Electrical Discharge Machining (WEDM) has established itself for manufacturing of precise and complex shape components for aerospace application due to the high quality requirement of aerospace components such as normal residual stress, no cracks, no recast layer, no porosity; still there is a need to optimize the control parameter settings and evaluate the performance characteristics of the WEDM process. The experiments have been conducted on Inconel 706 which is a newly-developed superalloy specially for aircraft application. A hybrid approach has been used to optimize the material removal rate (MRR) as well as surface roughness (SR) and significant control parameters have been identified using analysis of variance (ANOVA). Microstructure analysis revealed the formation of microglobules, melted debris and microholes on the machined surface, but no microcrack was detected due to the high toughness of the alloy. Energy dispersive X-ray spectroscopy (EDAX) has been carried out to study the metallurgical changes in the WED machined surface. The topography analysis of the curved surface revealed the best surface quality of the machined component at low pulse on time and high pulse off time. A thick recast layer of 39.6 µm was observed at high pulse on time and low servo voltage. Microhardness of the machined surface was changed up to a depth of 70 µm due to cyclic thermal loading during the WEDM process.

Journal ArticleDOI
TL;DR: In this article, the cylindrical permanent magnet tool with magnetorheological polishing fluid at its tip surface is rotated over the copper alloy workpiece surface and performs finishing by the stiffened magnetoric polishing fluids, and the results obtained from finite element analysis and experimentation assure that the new design of permanent magnetors is capable to nano-finish of diamagnetic materials such as copper alloy etc.
Abstract: Nano-finishing of a material surface is one of the most required properties in industry. There is high need of nano-finishing of diamagnetic materials such as copper and its alloys in electronic industries and electrode of electric discharge machining. Some industries like laser, aerospace, dentistry and metal optics etc. widely use highly finished copper mirrors. As copper is soft and chemically reactive material, its surface finishing at nano level is a difficult tasked. To fulfill this need, a new magnetorheological technique for precise surface finishing of diamagnetic materials has been conceptualized. Two cylindrical permanent magnets along with magnetorheological polishing fluid have been used to finish the diamagnetic copper alloy workpiece. The cylindrical permanent magnets tool with magnetorheological polishing fluid at its tip surface is rotated over the copper alloy workpiece surface and performs finishing by the stiffened magnetorheological polishing fluid. The permanent magnets finishing tool along with magnetorheological polishing fluid at its tip surface and diamagnetic copper workpiece have been modeled as well as simulated in Maxwell Ansoft V13 (student version) software. Distribution of magnetic flux density in the working gap is obtained and analyzed. Experiments are performed on the copper alloy workpiece and least Ra value of 28.8 nm is achieved in finishing time of 7.5 min from its initial value of 273.6 nm. Surface characteristics of both polished and unpolished workpiece are analyzed with the scanning electron microscopy (SEM) and atomic force microscopy (AFM). The results obtained from finite element analysis and experimentation assures that the new design of magnetorheological finishing tool using permanent magnets is capable to nano-finish of diamagnetic materials such as copper alloy etc.

Journal ArticleDOI
TL;DR: In this paper, the influence of the process parameters of conventional and non-conventional machining on the performance of metal matrix composites is discussed, and the research gaps and future scopes for further investigations in this field are identified.
Abstract: Abstract Metal matrix composites (MMCs) are the new-generation advanced materials that have excellent mechanical properties, such as high specific strength, strong hardness, and strong resistance to wear and corrosion. All these qualities make MMCs suitable material in the manufacture of automobiles and aircraft. The machining of these materials is still difficult due to the abrasive nature of the reinforced particles and hardness of MMCs. The conventional machining of MMCs results in high tool wear and slow removal of materials, thereby increasing the overall machining cost. The nonconventional machining of these materials, on the contrary, ensures much better performance. This paper reviews various research works on the development of MMCs and the subsequent hybrid composites and evaluates their performances. Further, it discusses the influence of the process parameters of conventional and nonconventional machining on the performance of MMCs. At the end, it identifies the research gaps and future scopes for further investigations in this field.

Journal ArticleDOI
TL;DR: The electrical discharge machining (EDM) technique was performed under the magnetic field influence to determine the material removal mechanism as well as surface roughness of nonmagnetic mate as mentioned in this paper.
Abstract: The Electrical Discharge Machining (EDM) technique was performed under the magnetic field influence to determine the material removal mechanism as well as surface roughness (SR) of nonmagnetic mate...

Journal ArticleDOI
TL;DR: In this article, a systematic view on evaluating the machining characteristics of wire cut electrical discharge machining (WEDM) employing Taguchi Method and Grey Relational Analysis based multiobjective optimization is provided.
Abstract: A systematic view on evaluating the machining characteristics of Wire Cut Electrical Discharge Machining (WEDM) employing Taguchi Method and Grey Relational Analysis based multiobjective optimization is provided in this research article. The outcome of various WEDM processing parameters including pulse discharge on time (PulseON), pulse discharge off time (PulseOFF), wire feed rate (WireFR) along with the material characteristics of varying Boron Nitride (BN) volume fractions while machining a friction stir processed (FSPed) copper-BN surface composite was investigated. The output responses considered in this research include Material Removal Rate (MRR) and Surface roughness (Ra) that was obtained from the L27 orthogonal array based on the above said input factors. ANOVA was performed, and PulseON and BN volume fraction were found most significant for MRR, while PulseON and PulseOFF influence the most in attaining minimal Ra values. Based on the obtained experimental values for MRR and Ra, a mathe...

Journal ArticleDOI
05 Jun 2018
TL;DR: In this paper, an attempt has been made to carry out multi-objective optimization of the material removal rate and roughness parameter (Ra) for the EDM process of EN31 on a CNC EDM machine using copper electrode through evolutionary optimization techniques like particle swarm optimization (PSO) technique and biogeography based optimization (BBO) technique.
Abstract: Electrical discharge machining (EDM) is a non-conventional machining process that is used for machining of hard-to-machine materials, components in which length to diameter ratio is very high or products with a very complicated shape. The process is commonly used in automobile, chemical, aerospace, biomedical, and tool and die industries. It is very important to select optimum values of input process parameters to maximize the machining performance. In this paper, an attempt has been made to carry out multi-objective optimization of the material removal rate (MRR) and roughness parameter (Ra) for the EDM process of EN31 on a CNC EDM machine using copper electrode through evolutionary optimization techniques like particle swarm optimization (PSO) technique and biogeography based optimization (BBO) technique. The input parameter considered for the optimization are Pulse Current (A), Pulse on time (µs), Pulse off time (µs), and Gap Voltage (V). PSO and BBO techniques were used to obtain maximum MRR and minimize the Ra. It was found that MRR and SR increased linearly when discharge current was in mid-range however non-linear increment of MRR and Ra was found when current was too small or too large. Scanning Electron Microscope (SEM) images also indicated a decreased Ra. In addition, obtained optimized values were validated for testing the significance of the PSO and BBO technique and a very small error value of MRR and Ra was found. BBO outperformed PSO in every aspect like computational time, less percentage error, and better optimized values.

Journal ArticleDOI
TL;DR: In this paper, a sustainable manufacturing technique known as magnetic field-assisted EDM (MF-EDM) is presented to enhance the machine characteristics for the purpose of reducing the energy consumption and environmental hazards of the conventional EDM machining Ti6Al4V.