Response Surface Approach for Optimization of Sinker Electric Discharge Machine Process Parameters on AISI 4140 Alloy Steel

Vishwakarma, Manish; Khare, Vikas; Parashar, Vishal

doi:10.13005/msri/090113

Cited by 6 publications

(4 citation statements)

References 9 publications

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“…R-sq. was obtained to be within the limit [39][40][41]. The close relation of the R-square values signifies the model is appropriate for predicting the future outcomes of MRR [42].…”

Section: Analysis Of Mrrmentioning

confidence: 63%

Multi-Response Optimization of Abrasive Waterjet Machining of Ti6Al4V Using Integrated Approach of Utilized Heat Transfer Search Algorithm and RSM

et al. 2021

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Machining of Titanium alloys (Ti6Al4V) becomes more vital due to its essential role in biomedical, aerospace, and many other industries owing to the enhanced engineering properties. In the current study, a Box–Behnken design of the response surface methodology (RSM) was used to investigate the performance of the abrasive water jet machining (AWJM) of Ti6Al4V. For process parameter optimization, a systematic strategy combining RSM and a heat-transfer search (HTS) algorithm was investigated. The nozzle traverse speed (Tv), abrasive mass flow rate (Af), and stand-off distance (Sd) were selected as AWJM variables, whereas the material removal rate (MRR), surface roughness (SR), and kerf taper angle (θ) were considered as output responses. Statistical models were developed for the response, and Analysis of variance (ANOVA) was executed for determining the robustness of responses. The single objective optimization result yielded a maximum MRR of 0.2304 g/min (at Tv of 250 mm/min, Af of 500 g/min, and Sd of 1.5 mm), a minimum SR of 2.99 µm, and a minimum θ of 1.72 (both responses at Tv of 150 mm/min, Af of 500 g/min, and Sd of 1.5 mm). A multi-objective HTS algorithm was implemented, and Pareto optimal points were produced. 3D and 2D plots were plotted using Pareto optimal points, which highlighted the non-dominant feasible solutions. The effectiveness of the suggested model was proved in predicting and optimizing the AWJM variables. The surface morphology of the machined surfaces was investigated using the scanning electron microscope. The confirmation test was performed using optimized cutting parameters to validate the results.

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“…R-sq. was obtained to be within the limit [39][40][41]. The close relation of the R-square values signifies the model is appropriate for predicting the future outcomes of MRR [42].…”

Section: Analysis Of Mrrmentioning

confidence: 63%

Multi-Response Optimization of Abrasive Waterjet Machining of Ti6Al4V Using Integrated Approach of Utilized Heat Transfer Search Algorithm and RSM

et al. 2021

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“…Powders with specific materials are added to the dielectric fluid to improve its breakdown characteristic. The series discharges caused by the powders enlarge the sparking gap, which can facilitate the removal of the debris and stable machining process [142][143][144]. The added powder would be energised and move in a zigzag fashion during the pulse-on time.…”

Section: The Effects Of Dielectric Fluids and Flowmentioning

confidence: 99%

The state of the art of electrical discharge drilling: a review

Mao

Almeida

et al. 2022

Int J Adv Manuf Technol

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Electrical discharge machining (EDM) is one of the most widely used non-conventional methods to machine electrically conductive materials in the manufacturing industry because of its strong capability in machining difficult-to-cut materials irrespective of their strength and hardness. Electrical discharge drilling (EDD) is an important variant of EDM. Due to the limitation of conventional drilling processes, special holes, particular those with high aspect ratios on hard-to-cut materials, can only be drilled by EDD. Extensive research has been carried out to improve the efficiency and quality of the EDD process by using different approaches, such as assisted EDD and powder-mixed EDM drilling aiming to improve the material removal rate (MRR), tool wear rate (TWR), surface quality and accuracy. This paper provides a comprehensive review of the EDD process. Different methods were compared; the advantages and disadvantages of each process were summarised; state-of-the-art technologies and the latest development were introduced, and research trends and new directions were presented.

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“…They found that multi hole inner flushing bunched electrode suffers much greater peak current and results in higher MRR and high. Manish Vishwakarma et al (2012) were carried out [11] investigation study to determine the process optimal factors viz. pulse on time, input current, duty cycle gap voltage, flushing pressure for machining AISI 4140 grade steel alloy rectangular plates on output responses through RSM using the technique of DOE, ANOVA based on the CCD.…”

Section: IIImentioning

confidence: 99%

Experimental Investigations into the Effect of Process Parameters on Performance Measures of Sink EDM Process: A Review Year 2011 To 2015 and Future Work

Choudri¹,

Gorabal²

2016

IJERT

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Sink Electrical Discharge Machining (Sink EDM) is a one of the important NTM process wherein electrically conductive work pieces are melted, vaporized (thermal erosion) by immersing in a dielectric fluid; tool electrode and work piece between the DC supply two poles either positive or negative and electric discharges takes place produces very high temperature in few micro seconds. It is widely used in defense, aerospace, automotive, micro systems, mould and die making industries. Recently researchers have discovered many ways to improve process parameters for achieving higher MRR, lower TWR and better surface quality. The paper reviews the works carried out from 2011 to till 2015. It reports on the research related to improve performance measures. The primary objective of analysis is to optimize the process parameters with the help of taguchi robust design methodology, design of experiment (DOE), analysis of variance(ANOVA), signal to noise ratio(S/N ratio, analysis of means (ANOM), face centered or rotational central composite design (CCD), scanning electron microscopy (SEM), X ray diffraction (XRD), response surface methodology (RSM), gray relational analysis (GRA), atomic force microscopy (AFM), energy dispersive spectroscopy (EDS), multiple regression analysis (MRA), mass spectrometry, optical microscopy techniques, fractional factorial design(FFD) with CCD and finite element analysis (FEM), etc. In end of the paper suggestions useful for future work has been indicated.

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Response Surface Approach for Optimization of Sinker Electric Discharge Machine Process Parameters on AISI 4140 Alloy Steel

Cited by 6 publications

References 9 publications

Multi-Response Optimization of Abrasive Waterjet Machining of Ti6Al4V Using Integrated Approach of Utilized Heat Transfer Search Algorithm and RSM

Multi-Response Optimization of Abrasive Waterjet Machining of Ti6Al4V Using Integrated Approach of Utilized Heat Transfer Search Algorithm and RSM

The state of the art of electrical discharge drilling: a review

Experimental Investigations into the Effect of Process Parameters on Performance Measures of Sink EDM Process: A Review Year 2011 To 2015 and Future Work

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