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

Abstract

Magnetic field assisted powder mixed electrical discharge machining (MFAPM-EDM) process is a hybrid process machining process which improves the machining characteristics and stability of process using assistive magnetic field and dielectric admixed powder. In this article, study on overcut has been performed on MFAPM-EDM machined Aluminium 6061 alloy. Discharge current, powder concentration, pulse on duration, pulse off duration, and magnetic field strength as process parameters have been varied during experimentation. Box Behnken design approach was employed for experimental design to carry out the experiments. Suitable Semi-empirical model was formulated using dimensional analysis for predicting the overcut. The empirical model developed was also compared with RSM model and was found better in predicting the response. Optimum process parameters for minimal overcut was conducted desirability function approach of RSM. Experimental results divulged discharge current as the most important parameters for overcut as compared to other process parameters on account of higher F-value. Confirmatory experiments revealed good correlation between optimum and experimental results.

Development and Investigation of an Inexpensive Low Frequency Vibration Platform for Enhancing the Performance of Electrical Discharge Machining Process

“…Equations ( 3)- (5) give the correlation between the surface roughness, MRR and TWR with the process variables, respectively. The following sections discuss the regression equations, the analysis of variance, and the influence of the process parameters on the responses to evaluate the process performance.…”

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Utilizing multiple criteria decision-making optimization methods to machine LM25Al/VC material under electro-discharge machining processes

“…These variables can be analyzed by MCDM methods. In the same way, multi-objective approaches also have difficulties achieving many goals at the same time [28]. Various approaches, such as metaheuristics, Pareto-based strategies, and multi-model independent direction, are used to address improvement challenges.…”

Temperature Optimization by Using Response Surface Methodology and Desirability Analysis of Aluminium 6061

“…The results of the trials revealed that the discharge current is the most relevant parameter. The optimum process parameters for minimal overcut (OC) is 0.0801 mm was observed with a desirability index of 0.998 [ 13 ].…”