Optimization of machining parameters of WEDM for Nimonic-75 alloy using principal component analysis integrated with Taguchi method

Sonawane, Sachin Ashok; Kulkarni, M. L.

doi:10.1016/j.jksues.2018.04.001

Cited by 52 publications

(29 citation statements)

References 22 publications

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“…For example, Hegab et al [16] optimized material removal rate, wear electrode ratio, and average surface roughness Ra as a function of machining on-time, discharge current, voltage, total depth of cut and percentage in weight of carbon nanotube composites (CNT) added to an aluminum base. Sonawane et al [17] considered WEDM parameters such as pulse-on time, servo voltage, pulse-off time, peak current, feed rate, and cable tension and responses like surface roughness, overcut and material removal rate, in Nimonic-75 alloy. Magabe et al [18] investigated the effect of spark gap voltage, pulse on-time, pulse off-time, and wire feed on the material removal rate and surface roughness of a Ni-Ti shape memory alloy.…”

Section: Introductionmentioning

confidence: 99%

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

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Cam-follower mechanisms are usually employed in different machines, like combustion engines, sewing machines, machine tools, etc. In the present paper, the option to manufacture cams utilizing wire electrical discharge machining (WEDM) has been considered. For this, surface roughness and shape error of cam profiles manufactured by the processes of milling and wire electrical discharge machining (WEDM) are presented. The methodology used covers different stages: design, prototyping, manufacturing, and measurement of the cams. As a reference, a cam-follower mechanism from a motorcycle internal combustion engine has been used. A reverse engineering process has been performed to determine the geometrical parameters of the mechanism, which are used for the synthesis of the profile of the cam and its subsequent design. The manufacturing process of the cams has been assisted by CAD-CAM (Computer Assisted Drawing-Computer Assisted Manufacturing) software. Using fused filament fabrication (FFF), a physical prototype of the cam has been manufactured, in order to validate the goodness of the design. Finally, the roughness and shape parameters have been measured on the contour surface of the cams. The arithmetical mean roughness Ra value of the milled cam was 0.269 μm, below the requirement of 0.4 μm, and shape error was 18 μm, below 50 μm. Shape error of the WEDM cam of 48 μm meets the requirements for cams. However, the Ra value of 1.212 μm, exceeded the limit. For this reason, a finish operation is recommended in this case. Some advantages of WEDM cams over milled cams are that different conductive materials can be employed, more complex shapes can be obtained, and that, in rough operations, the amount of material to be removed in subsequent operations is considerably reduced.

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Section: Introductionmentioning

confidence: 99%

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

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“…None of the produced samples has subsurface defects in the form of burnt cavities or cracks, which is very favourable in terms of the required functionality and durability of parts machined in this way. Given similar studies such as Goswami [11,17], Bisaria [15] or Sonawane [16], it can be said that Nimonic material does not tend to form subsurface cracks after WEDM, which is a very positive fact. The analysis of the subsurface layer was performed on pre-prepared metallographic preparations of all samples using electron microscopy.…”

Section: Multicriteria Optimizationmentioning

confidence: 94%

“…They focused their attention on the surface morphology and topography, recast layer thickness and surface roughness among the others. Sonawane [16] focused on the machining parameters optimization during the WEDM process and studied Nimonic-75 as a material for the experiments. In their research, they employed principal component analysis, which they combined with the Taguchi method.…”

Section: Literature Reviewmentioning

confidence: 99%

Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

et al. 2020

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Wire electrical discharge machining (WEDM) is an unconventional and very efficient technology for precision machining of the Nimonic C 263 super alloy, which is very widespread, especially in the energy, aerospace and automotive industries. Due to electrical discharge, defects in the form of cracks or burned cavities often occur on the machined surfaces, which negatively affect the correct functionality and service life of the manufactured components. To increase the efficiency of the machining of Nimonic C 263 using WEDM, in this study, extensive design of experiments was carried out, monitoring input factors in the form of machine parameters like Pulse off time, Gap voltage, Discharge current, Pulse on time and Wire feed, the output of which was comprehensive information about the behaviour of such machined surfaces, which allowed the optimization of the entire machining process. Thus, the optimization of the Cutting speed was performed in relation to the quality of the machined surface and the machining accuracy, as well as an analysis of the chemical composition of the machined surfaces and a detailed analysis of the lamella using a transmission electron microscope. A detailed study of the occurrence of surface or subsurface defects was also included. It was found that with the help of complex optimization tools, it is possible to significantly increase the efficiency of the machining of the Nimonic C 263 super alloy and achieve both financial savings in the form of shortened machine time and increasing the quality of machined surfaces.

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“…PCA is a powerful multivariate statistical technique for multi-objective optimization [ 20 ] that reduces the complexity, correlation, vagueness, and dimensions of information by simplifying and combining numerous allied arrays into few uncorrelated arrays and principal component. PCA employs linear permutation for conserving unique information to maximum extent [ 45 ]. Thus, it converts multi-response optimization to single response optimization without compromising original information [ 46 ].…”

Section: Optimization Methodologymentioning

confidence: 99%

An Integrated Approach of GRA Coupled with Principal Component Analysis for Multi-Optimization of Shielded Metal Arc Welding (SMAW) Process

et al. 2020

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Welding distortion is a critical issue as it leads to severe deterioration of structural integrity of welded work piece and dimensional precision. This study aims at studying the effects of shielded metal arc welding (SMAW) parameters on the evolution of mechanical properties, including tensile strength, impact toughness, and hardness, along with angular distortion on a welded joint from SA 516 grade 70. Such parameters are analyzed and optimized by employing the Taguchi method and Grey relational analysis. SA 516 grade 70 is commercially used for fabrication of storage tanks, boilers and pressure vessels. SMAW is investigated with three levels of root gap, groove angle, electrode diameter, and pre-heat temperature, which were varied on a butt joint in flat (1 G) position to determine their effects on response variables at room temperature. Nine experiments were designed using a Taguchi L9 orthogonal array, welded according to American Society of Mechanical Engineers (ASME) section IX, and samples were prepared and tested as per ASTM A 370. The Taguchi method and Grey relational analysis were employed to observe the most significant parameters and optimal levels that synergically yield improved responses. Results are validated by conducting confirmatory experiments that show good agreement with optimum results.

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Optimization of machining parameters of WEDM for Nimonic-75 alloy using principal component analysis integrated with Taguchi method

Cited by 52 publications

References 22 publications

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Precision Machining of Nimonic C 263 Super AlloyUsing WEDM

An Integrated Approach of GRA Coupled with Principal Component Analysis for Multi-Optimization of Shielded Metal Arc Welding (SMAW) Process

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