Optimization of process parameters in magnetic field assisted powder mixed EDM of aluminium 6061 alloy

Abstract

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) is a variant of EDM process where magnetic field coupled with electric field is used with addition of fine powder in dielectric to improve the surface quality, machining rate and stability of the process. Aluminium 6061 alloy as workpiece was selected due to growing use in aviation, automotive, naval industries. In this present work, parametric study and optimization was carried out on MFAPM-EDM machined Aluminium 6061 alloy. In this study, process parameters such as discharge current (IP), spark duration (PON), pause duration (POFF), concentration of powder (CP) and magnetic field (MF) were considered to analyze the effect on material erosion rate (MER) and electrode wear rate (EWR). Box Behnken design approach based on response surface methodology (RSM) was utilized for performing the experiments. Quadratic model to predict the MER and EWR were developed using response surface methodology. Discharge current has most significant effect of 50.176% and 36.36% on MER and EWR, respectively among all others process parameters. Teacher-learning-based optimization (TLBO) was employed for determining the optimal process parameters for maximum MER and minimal EWR. The results obtained with TLBO was compared with well-known optimization methods such as genetic algorithm (GA) and desirability function of RSM. Minimum EWR (0.1021 mm3/min) and maximum MER (30.4687 mm3/min) obtained using TLBO algorithm for optimized process parameters was found to better as compared to GA and desirability function.

Semi-empirical modeling and optimization of process parameters on overcut during MFAPM-EDM of Al6061 alloy

“…MFAPM-EDM process mechanism of material removal. 13,30 more charges. Thus, early explosion occurs in the parking zone causing increase in spark frequency.…”

“…Rouniyar and Shandilya 13 machined Al6061 alloy with MFAPM-EDM process, witness rise in MRR and reduction in TWR with Al powder admix with dielectric and assisted by magnetic field. Rouniyar and Shandilya 30 investigated effect of process parameters on MER and EWR, optimized process parameters for maximum MER and EWR using TLBO. Rouniyar and Shandilya 31 observed decrease in SR during EDM of Al6061 alloy with Al powder mixed in EDM oil and presence of magnetic field.…”

“…Figure 2. (a) Discharge phenomenon in the sparking zone (b) Different phases of discharge and (c) Magnetic field system in MFAPM-EDM process 13,30. …”

Optimization of machining parameters in chromium-additive mixed electrical discharge machining of the AA7075/5%B4C composite

“…From the ANOVA Table 7 given below, it can be seen that the model developed is significant as the F-value is recorded as 40.17. The model terms A, B, D, AB, AC, AD, D2, possess P-value <0.05, which justifies the significance of the term on SR. 14 The 'lack of fit F-value' of 1.70 suggests the non-significance of lack of fit in relation to pure error. To obtain an appropriate model, the lack of fit is desired to be non-significant, which occurred in the present case.…”

Study of the performance parameters of friction stir welded magnesium AZ31B alloy at optimized process parameters

“…The F-value defines the dispersion of the parameter. The immense F-value indicates more excellent dispersion 40 . The square of WS has a higher F-value followed by RS and WS for tensile strength, whereas WS has a higher F-value for El, IMP and MH.…”