Optimization of Electric Discharge Machining of M2 Tool Steel Using Grey Relational Analysis

Purohit, Rajesh; Rana, R.S.; Dwivedi, Rinky; Banoriya, Deepen; Singh, Swadesh Kumar

doi:10.1016/j.matpr.2015.07.312

Cited by 23 publications

(7 citation statements)

References 5 publications

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“…The EDM process parameters were optimized using a gray relation approach during machining of M2 steel. The electrode rotational speed majorly affects the MRR, electrode wear rate, and overcut followed by voltage and spark time (Purohit et al 2015). Lin et al (Lin et al 2006) analyzed the material removal and surface roughness on the process parameters during WEDM of SKD11 steel.…”

Section: Introductionmentioning

confidence: 99%

Parametric optimization of MRR and surface roughness in wire electro discharge machining (WEDM) of D2 steel using Taguchi-based utility approach

Manjaiah

Laubscher

Kumar

et al. 2016

Int J Mech Mater Eng

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Background: This paper reports the effect of process parameters on material removal rate (MRR) and surface roughness (Ra) in wire electro discharge machining of AISI D2 steel. Findings: The wire electro discharge machining characteristics of AISI D2 steel have been investigated using an orthogonal array of design. The pulse on time and servo voltage are the most significant parameter affecting MRR and surface roughness during WEDM process. The simultaneous performance characteristics MRR and surface roughness was optimized by Taguchi based utility approach. The machined surface hardness is higher than the bulk material hardness due to the repetitive quenching effect and contained various oxides in the surface recast layer. Methods: The experiments were performed by different cutting conditions of pulse on time (T on ), pulse off time (T off ), servo voltage (SV) and wire feed (WF) by keeping work piece thickness constant. Taguchi L 27 orthogonal array of experimental design is employed to conduct the experiments. Multi-objective optimization was performed using Taguchi based utility approach to optimize MRR and Ra. Results: Analysis of means and variance on to signal to noise ratio was performed for determining the optimal parameters. It reveals that the combination of Ton3, Toff1, SV1, WF2 parameter levels is beneficial for maximizing the MRR and minimizing the Ra simultaneously. The results indicated that the pulse on time is the most significant parameter affects the MRR and Ra. Concludions: The melted droplets, solidified debris around the craters, cracks and blow holes were observed on the machined surface for a higher pulse on time and lower servo voltage. Recast layer thickness increased with an increase in pulse on time duration. The machined surface hardness of D2 steel is increased due to the repetitive quenching effect and formation oxides on the machined surface.

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Section: Introductionmentioning

confidence: 99%

Parametric optimization of MRR and surface roughness in wire electro discharge machining (WEDM) of D2 steel using Taguchi-based utility approach

Manjaiah

Laubscher

Kumar

et al. 2016

Int J Mech Mater Eng

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“…GRA is applied for assessing the dependent parameter influence with meager data information [25]. In grey approach, pre-processing of raw data's is made initially for further analysis, pre-processing is done by converting the data points to some type of indices for quantification purposes through normalizing procedure [26]. The experimental output values should be converted to decimal values between zero and one for assessing in normalizing stage [27].…”

Section: International Journal Of Innovative Technology and Exploringmentioning

confidence: 99%

Performance of Zinc Coated Electrode Wire and Parametric Optimization During Profile Cutting of Die-Steel

Saravanan*,

Thiyagarajan,

Somasundaram

2020

IJITEE

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In this work, the effect of brass wire coated with zinc as electrode wire towards maximizing MRR and minimizing SR for the considered input parameters was studied in elaborate during profile cutting of tool steel AISI D3. Experiments were designed based on the L18(21 ,37 ) Taguchi’s orthogonal array considering cutting speed, Ton and Toff, wire tension, servo feed rate and voltage, current and electrode feed rate. The outputs MRR and SR were analyzed and optimized using Grey Relational Analysis (GRA) simultaneously. For both SR and MRR, the drawn chart shows that, the raw data’s lies within upper and lower control limits. The optimum input conditions obtained for higher MRR and lower SR were: 75% of cutting speed, 128 µsec of Ton, 54µsec of Toff, 190A of input current, electrode feed of 3 mm/min with 7 gm of electrode tension, 10V of servo voltage and 2060 mm/min of 10V. Execution of ANOVA on grey grade identifies that, wire tension was the parameter that influences more by 25.89%, followed by Ton and servo voltage by 21.37% and feed rate of wire by 11.89%, with an R2 value of 96.55%. For validating the results, confirmation experiment was also done

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“…Brass rod the electrode that drills through blind hole on tool steel M2 was analyzed using EDM [13]. The output parameters are MRR, electrode wear ratio (EWR), and over cut (OC), and the input parameters are tool revolution speed, voltage and spark time.…”

Section: Literature Reviewmentioning

confidence: 99%

Experimental Investigation of Drilling Small Hole on Duplex Stainless Steel (SS 2205) Using EDM

Rajaram¹,

Rajkumar²,

Balasundaram³

et al. 2019

Mechanics and Mechanical Engineering

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This work investigates drilling of small holes of 3 mm in diameter on duplex stainless steel. Its machinability index is very low (0.66) when compared to other steels; hence, electrical discharge machining is used. The input parameters are current, spark gap, and dielectric pressure. Each input parameter is considered for three levels. Therefore, the total number of experiments is 3 × 3 × 3 = 27. To reduce the number of runs, Taguchi L9 orthogonal array is used, which have the advantage of maximum and minimum trial runs in its design. The output response is metal removal rate (MRR). To find the best operating parameter, the regression model generated using ANOVA is given as input for MATLAB genetic algorithm (GA). The experimental results indicated that models are significant. The test result indicated that the contribution of the current on the MRR is 42.42%, dielectric pressure is 35.36%, and spark gap is 1.93%. From GA, it is observed that among these three factors, lower value of current and dielectric pressure produced the maximum MRR. The SS 2205 has wide variety of applications, such as high pressure components and control valves, which have large number of components attached to it. Hence, performing micro holes on such high hardness alloy is useful.

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Optimization of Electric Discharge Machining of M2 Tool Steel Using Grey Relational Analysis

Cited by 23 publications

References 5 publications

Parametric optimization of MRR and surface roughness in wire electro discharge machining (WEDM) of D2 steel using Taguchi-based utility approach

Parametric optimization of MRR and surface roughness in wire electro discharge machining (WEDM) of D2 steel using Taguchi-based utility approach

Performance of Zinc Coated Electrode Wire and Parametric Optimization During Profile Cutting of Die-Steel

Experimental Investigation of Drilling Small Hole on Duplex Stainless Steel (SS 2205) Using EDM

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