Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

Abstract

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

Teaching-Learning-Based Parametric Optimization of an Electrical Discharge Machining Process

“…Analytic hierarchy process (AHP) was utilized to estimate relative weights of the considered responses. While employing response surface methodology (RSM)-based regression models, Niamat et al [22] endeavored to study the influences of current, pulse-on time and pulse-off time on MRR, SR and TWR in an EDM process. Multi-objective optimization was also performed to achieve sustainability while optimizing the conflicting responses.…”

Energy Efficiency of Manufacturing Processes and Systems—An Introduction

“…The list of papers presented includes the following: In the following paragraphs, a brief review of these papers is provided. Niamat et al [1] investigated the use of electro-discharge machining process for sustainable manufacturing. Their focus was on optimizing the process parameters, such as pulse on time, current and pulse off time and finding a tradeoff between quality of final produced part, productivity and cost.…”

Parametric Optimization for Quality of Electric Discharge Machined Profile by Using Multi-Shape Electrode

“…EDM objectives are well defined, such as lower tool wear rate, better surface finish rates, lower power consumptions and high material removal rate. The latest optimization techniques used in EDM provide better-quality at lower costs and power consumptions [ 28 ]. Every method employed in the EDM process has the same targets: to enhance the capability of machining performance by adopting the better working conditions and to develop techniques to machine new materials [ 29 , 30 ].…”