Optimal parameter prediction of oxygen-mist near-dry wire-cut EDM

Boopathi, S.; Sivakumar, K.

doi:10.1504/ijmtm.2016.077812

Cited by 48 publications

(25 citation statements)

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“…2. Based on the analysis of the variance test, the significant individual and interaction and quadratic terms were identified [5]. In-significant terms are eliminated from the model.…”

Section: Wwr =mentioning

confidence: 99%

“…The analytical relationship of EDM processes was developed to reveal the wear of the tool and workpiece, and the dielectric fluid flows, and the toxicity and flammability [3] and [4]. The inferences of cooling electrode wear and surface roughness of the workpiece have been Investigated by the change of process parameters such as voltage, pulse-width, current, and pulse-interval [5] and [6]. The parametric analysis of dry electric discharge machining of mild steel was investigated and response models were developed by response surface methodology [7].…”

Section: Introductionmentioning

confidence: 99%

“…The cryogenically teated brass wire produces 22.55 % more material removal rate (MRR) compared to untreated brass wire [9]. The parametric study was performed using a molybdenum wire tool and tool steel workpiece with an air dielectric to invetigated the influence of air-mist pressure, voltage, pulseduration, pulse-width, and current on the MRR and Ra using the Taguchi technique [5] and [10]. Later, the oxygen gas near-dry WEDM experiments have been conducted using Taguchi's L27 orthogonal array and multi-objective artificial bee colony (MOABC) algorithm [11] and [12].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Boopathi¹,

Myilsamy²

2021

SV-JME

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In this paper, a novel method of cryogenically cooled (low-temperature nitrogen gas) wire tool is used during the oxygen-mist near-dry wire-cut electrical discharge machining (NDWEDM) process to cut Inconel 718 alloy material. The current, pulse-width, pulse-interval, and flow rate are the controllable variables for response characteristics, such as the material removal rate (MRR) and wire wear ratio (WWR). The Box-Behnken method is applied to design the experiments to collect the observations from experiments. The mathematical models for each response were developed using significant individual, interaction, and quadratic terms by the sequential sum of the square test. The response surfaces were developed. It was revealed from the analysis that 52.92 % of current, 24.63 % of Pulse-width, 12.81 % of pulse- interval and 5.75 % of flow rate contributed to MRR, while 14.89 % of current, 9.75 % of pulse-width, 62.20 % of pulse-interval, and 5.44 % of flow rate contributed to WWR. The pulse-width has more contribution on MRR due to the long period of spark between the wire and work materials. It was also observed that the pulse-interval has more effect on WWR due to the more ideal period (high spark-pause-time) between two consecutive high-temperature sparks in the wire tool. The wear of the wire tool has been analysed using scanning electron microscopy (SEM) photographs. The desirability principles were first applied to obtain multi-objective solutions with a combination of process parameters to achieve the optimal values of both responses. The predicted combination of results has been validated by data that were collected from confirmation experiments.

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“…2. Based on the analysis of the variance test, the significant individual and interaction and quadratic terms were identified [5]. In-significant terms are eliminated from the model.…”

Section: Wwr =mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Boopathi¹,

Myilsamy²

2021

SV-JME

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show abstract

“…Based on the Taguchi quality design concept, the values of the control parameters are assigned to the various level of L27 orthogonal array and shown in Table 1. The experiments were conducted in a random manner to avoid bias error [27]. The 27 observations are replicated 3 times to exclude the experimental exceptions [25].…”

Section: Taguchi Design Of Experimentsmentioning

confidence: 99%

Experimental investigation and parameter analysis of LPG refrigeration system using Taguchi method

Boopathi¹

2019

SN Appl. Sci.

Self Cite

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In this research work, an attempt has been made to study the liquefied petroleum gas (LPG) as an alternative refrigerant to eliminate the global warming potential causes many dangerous impacts on the environment by conventional refrigerants. An LPG refrigeration experimental setup has been fabricated using different lengths of capillary tubes, pressure regulator, evaporator, LPG supply unit, and gas burner. Initially, the parameters working ranges have been confirmed by conducting Exploratory experiments. The evaporator temperature is considered as response parameter which gives the proportionate changes of coefficient of performance. The effects of selected input parameters on evaporated temperature have been investigated. The capillary tube internal diameter, length of capillary tube and system operating time has been selected as input parameters. It was observed from literature survey that there was very few systematic experimentation and statistical analysis were only performed. Thus, L27 Taguchi's design of experiment has been employed to conduct experiments and to identify the significant process parameters. The confirmation test has been conducted to validate the predicted result from the Taguchi method. It was observed that the evaporator temperature has been increased by increasing time of operation and coil diameter of capillary tube. However, the effect on inner diameter is directly proportionate to output response.

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“…The machining performance of the dry EDM/WEDM is low and unstable compared with conventional processes [15][16][17][18]. These downsides have been minimized by near-dry EDM and WEDM processes [10,16,19]. In the near-dry EDM/WEDM processes, the compressed air/gases mixed with the minimum amount of liquid/water are used as dielectric fluid [10,13,14,[18][19][20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

Boopathi¹,

Myilsamy²,

Sukkasamy³

2021

Preprint

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In this research, the mixing of compressed air with the minimum quantity of water is used as a dielectric medium and the cryogenically cooled molybdenum wire is used as a tool in wire-cut electrical discharge machining (WEDM) to encourage the eco-friendly production, called cryogenically cooled near-dry WEDM process. The nitrogen gas-cooled wire tool is utilized to cut the Inconel 718 alloy workpiece to prevent wire breakage and maintain enough electrical conductivity. The preliminary experiments were conducted to compare wet, dry, near-dry, and cryogenically cooled near-dry WEDM processes. It was revealed that cryogenic cooled near-dry WEDM is better performance than dry, near-dry WEDM except for the wet process. The systematic experiments of eco-friendly cryogenically cooled near-dry WEDM have been conducted to analyse the effect of input factors like spark current, pulse-width, pulse-interval, and mixing water flow rate on material removal rate (MRR) and surface roughness (SR) using Box–Behnken method. The fitted models and response surface graphs were developed to analyse the influences of input factors on each response parameter. It was concluded that MRR and SR of cryogenically cooled near-dry WEDM are increased by maximizing spark current, pulse-width, and flow rate, conversely, both responses were decreased by increasing pulse-interval. The technique for order of preference by similarity to ideal solution (TOPSIS) technique has been applied to predict the best combination of input factors for satisfying the optimal values of both responses.

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Optimal parameter prediction of oxygen-mist near-dry wire-cut EDM

Cited by 48 publications

References 0 publications

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental Investigation of a Cryogenically Cooled Oxygen-mist Near-dry Wire-cut Electrical Discharge Machining Process

Experimental investigation and parameter analysis of LPG refrigeration system using Taguchi method

Experimental Investigation and Multi-Objective Optimization of Cryogenically Cooled Near-Dry Wire-Cut EDM Using TOPSIS Technique

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