Optimization of CNC-WEDM Parameters for AA2024/ZrB2 in situ Stir Cast Composites Using Response Surface Methodology with Desirability Function Technique

Muralidharan, N. P.; Chockalingam, K.; Parameshwaran, R.; Kalaiselvan, K.; Nithyavathy, N.

doi:10.1007/s13369-020-04490-x

Cited by 14 publications

(5 citation statements)

References 25 publications

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“…From this study, the authors concluded that the proposed RSM model is the best method for developing the quality of the surface, which could be applied for industrial necessities. Muralidharan et al 36 studied the WEDM performance of AA2024–ZrB2 composites by using the RSM optimization method. From this examination, the authors concluded that the optimum parameters obtained from the RSM method are suggested for the aircraft component, namely fuselage.…”

Section: Introductionmentioning

confidence: 99%

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Sivasankaran¹,

Muralikannan²,

Ramkumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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A substantially developed machining process, namely wire electrical discharge machining (WEDM), is used to machine complex shapes with high accuracy. This existent work investigates the optimization of the process parameters of wire electrical discharge machining, such as pulse on time ( Ton), peak current ( I), and gap voltage ( V), to analyze the output performance, such as kerf width and surface roughness, of AA 4032–TiC metal matrix composite using response surface methodology. The metal matrix composite was developed by handling the stir casting system. Response surface methodology is implemented through the Box–Behnken design to reduce experiments and design a mathematical model for the responses. The Box–Behnken design was conducted at a confident level of 99.5%, and a mathematical model was established for the responses, especially kerf width and surface roughness. Analysis of variance table was demarcated to check the cogency of the established model and determine the significant process. Surface roughness attains a maximum value at a high peak current value because high thermal energy was released, leading to poor surface finish. A validation test was directed between the predicted value and the actual value; however, the deviation is insignificant. Moreover, a confirmation test was handled for predicted and experimental values, and a minimal error was 2.3% and 2.12% for kerf width and surface roughness, respectively. Furthermore, the size of the crater, globules, microvoids, and microcracks were increased by amplifying the pulse on time.

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Section: Introductionmentioning

confidence: 99%

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Sivasankaran¹,

Muralikannan²,

Ramkumar³

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…From this a length of 10 mm, width of 10 mm and height of 6 mm were cut by WEDM machine. All the experiments were made to run for a period of 15 min and the machining duration was estimated using a digital stopwatch with 0.1 s accuracy [16]. The composite material arrangement in WEDM setup is shown in Figure 3.…”

Section: Methodsmentioning

confidence: 99%

“…Authors published that enhancement of process parameters was performed using various researchers concerning to increase Material Removal Rate (MRR) and lower Surface Roughness (SR). To obtain effective parametric responses a multi-objective optimization is adopted [15,16]. RSM technique is utilized for the strategy of experimentation and utilized for optimization of parameters in process of WEDM of HSLA, CFRP, Al-SiC and TiB 2 (P) metal matrix composite (MMC) materials correspondingly.…”

Section: Introductionmentioning

confidence: 99%

Effect of Al7075 and activated carbon reinforced composite on optimizing WEDM responses

Ramanan,

R R,

Suresh

et al. 2024

Mater. Res. Express

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This paper presents wire cut electrical discharge machining (WEDM) response characteristics of Aluminium 7075 (Al7075) reinforced with powdered activated carbon (PAC) composite. In recent days WEDM has become a significant machining process in targeting its benefits of contributing improved material removal rate (MRR) and low surface roughness (SR). This is due the rising need for intricate, accurate, and superior structural components, the WEDM process emerges as a formidable alternative to traditional machine tools. In this work Pulse-on time (Ton), pulse-off time (Toff), discharge current (IA) and servo speed rate (SS) are the variables to be given as input and machining responses such as MRR and SR are studied. From Analysis of Variance (ANOVA) study it is found that discharge current and servo speed is the significant parameters. The optimal desirability condition is obtained with input parameters Ip: 2000 mA; Ton: 8.9 µs; Toff: 25 µs and SS: 150rpm for the precision machining. The optimum response parameters are found as MRR 10.46 mm3/min and SR 3.32 µm. Results shows that the model designed for the prediction of MRR produces an above 98.27 % and the prediction of SR is above 97.17 %. The error percentage among the experimental and predicted MRR and SR were estimated. Additionally confirmatory test is performed with optimal results achieved from response surface methodology (RSM) and desirability technique. Metallurgical tests like electron backscatter diffraction analysis (EBSD) and microstructure are conducted to confirm the surface properties and atomic force morphology (AFM) analysis is applied to clarify the structural features of machined composites. The results revealed that the variation of hard deflection is caused by depression of eroded materials on the top layers of machined surface.

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“…The main idea behind a desirability function is to transform multi-objective problems to a single equivalent objective function while keeping overall desirability into account. 42…”

Section: Multi-objective Optimization Of the Responsesmentioning

confidence: 99%

Investigation and multi-objective optimization of monocrystalline silicon wafering using wire electro-discharge machining

Verma

Singh

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Monocrystalline silicon wafers are widely used as the primary material for solar cell production in the photovoltaic industry, owing to their high efficiency and sleeker aesthetic. Wafering is the primary process towards wafer production. The existing wafering processes have limitations of cracking, chipping, and high kerf loss, arising the need for cost-efficient and precise methods to produce wafers. In the present experimental work, an attempt has been made to explore the potential of Wire Electro-discharge Machining (WEDM) for wafer production and to gain an understanding of the effects caused by pulse on time (Ton), pulse off time (Toff), peak current (Ip), wire tension (WT), and wire feed rate (WFR) during the wafering process to achieve the optimal parametric setting for attaining maximum wafering speed and minimum surface roughness. The work material used was P-type monocrystalline silicon. Wafers thickness of 250 μm was produced, avoiding edge chipping. The experimentation was planned according to the face-centered central composite design. The obtained results were statistically analyzed, and response surface methodology (RSM) was used to model the wafering speed and surface roughness. From the analysis of experimental results, it was noticed that at the higher level of Ton and Ip, a maximum wafering speed of 2.574 mm/min was attained. In contrast, the minimum surface roughness of 1.57 μm was achieved at the lower level of Ton and Ip. The most significant process variables that influence the wafering speed and surface roughness are the Ton, Toff, and Ip. Micrographs of the wafer surface reveal the presence of micro craters, but there was no evidence of micro-cracks. The multi-objective optimization of the responses was done using the desirability approach, and the optimized values of wafering speed and surface roughness attained were 0.989 mm/min and 1.57 μm, respectively.

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Optimization of CNC-WEDM Parameters for AA2024/ZrB2 in situ Stir Cast Composites Using Response Surface Methodology with Desirability Function Technique

Cited by 14 publications

References 25 publications

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Studies of kerf width and surface roughness using the response surface methodology in AA 4032–TiC composites

Effect of Al7075 and activated carbon reinforced composite on optimizing WEDM responses

Investigation and multi-objective optimization of monocrystalline silicon wafering using wire electro-discharge machining

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