Simultaneous optimization of multiple performance characteristics in WEDM for machining ZC63/SiCp MMC

Abstract

The compliance of an integrated approach, principal component analysis (PCA), coupled with Taguchi's robust theory for simultaneous optimization of correlated multiple responses of wire electrical discharge machining (WEDM) process for machining SiC P reinforced ZC63 metal matrix composites (MMCs) is investigated in this work. The WEDM is proven better for its efficiency to machine MMCs among others, while the particulate size and volume percentage of SiC p with the composite are the utmost important factors. These improve the mechanical properties enormously, however reduce the machining performance. Hence the WEDM experiments are conducted by varying the particulate size, volume fraction, pulse-on time, pulse-off time and wire tension. In the view of quality cut, the most important performance indicators of WEDM as surface roughness (R a), metal removal rate (MRR), wire wear ratio (WWR), kerf (K w) and white layer thickness (WLT) are measured as responses. PCA is used as multi-response optimization technique to derive the composite principal component (CPC) which acts as the overall quality index in the process. Consequently, Taguchi's S/N ratio analysis is applied to optimize the CPC. The derived optimal process responses are confirmed by the experimental validation tests results. The analysis of variance is conducted to find the effects of choosing process variables on the overall quality of the machined component. The practical possibility of the derived optimal process conditions is also presented using SEM. Keywords ZC63/SiC P metal matrix composites Á Wire electrical discharge machining (WEDM) Á Principal component analysis (PCA)-Taguchi method (TM) Á Analysis of variance (ANOVA)

Analysis of control factors and surface integrity during wire-EDM of Inconel 718 alloy using T-GRA approach

“…The findings of magnesium alloy in view of efficient machining operation with different facets of the performance and reliability of the magnesium alloy are discussed using wire-EDM [18], [19]. The findings of an experimental study on the selection of processing conditions that decide performance of wire-EDM using aluminium alloy and the optimization abilities of some output responses in wire-EDM of reinforced ZC63 metal matrix composite are discussed [20], [21]. Experimental investigation of performance measures using wire-EDM for alumium alloy-7017 and rolled homogeneous armor (RHA) steel shows favourable value [22].…”

A hybrid algorithm for adjusting the input parameters of the wirecut EDM machine in order to obtain maximum customer satisfaction

“…In another effort in 2013, Rajyalakshmi and Venkata Ramaiah, performed a multi-objective optimization for parts made of Inconel 825 with machine settings as independent variables and MRR, SR, and spark gap (SG) as dependent variables [11]. In the same year, Rao and Krishna studied the best input settings to optimize the values of wire wear and kerf width using harmony search for ZC63/SiCp MMC [12]. Also, Durairaj et al optimized SR and Kerf by using GRA [13], and then Shayan and others by applying RSM for SR, overcut, and cutting speed [14].…”

Experiments and optimization for the WEDM process: A trade-off analysis between surface quality and production rate

“…The outcomes revealed that the WEDM responses were influenced by the POT, POFT, and CA, respectively. Additionally, the R a , one of the most important indicators of the surface integrity was optimized in conjunction with other factors, including the cutting speed (CS) [8], wire wear ratio (WWR) [9], kerf width (KW) [10][11][12], and material removal rate (MRR) [13][14][15].…”

“…As a result, the effects of the varied conditions on machining responses for different WEDM operations have been performed. Different optimization techniques, such as the RSM [1,2,4,[6][7][8][9]13], Taguchi [3,14], grey relation analysis (GRA) [15], and hybrid approach [9,10,12] were utilized to resolve the optimizing issues. However, the published works regarding optimization in the WEDM performances have still the limitations.…”

“…Additionally, most of the studies found in the literature aimed to decrease the R a [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15]. Practically, R q is an important indicator of the roughness for the specific purpose of the machining case, which is necessary to address [18].…”