Multi-response optimization in wire electrical discharge machining (WEDM) of D2 steel using utility approach

Wire electrical discharge machining (WEDM) is a popular non-conventional machining process used particularly for making extrusion dies, blanking punches, and tools especially requiring tight dimensional tolerances. Because of the process limitation, the rate of cutting and maintenance of close dimensional tolerance is a challenging task. Given the above facts, the present work has been focused on achieving the maximum possible cutting rate (VC) maintaining good dimensional accuracy and corner radius (RC). In the present research work, a multi-response optimization method (i.e. Taguchi based Utility approach) has been used to obtain an optimum set of input parameters such as pulse on time (TON), pulse off time (TOFF), servo voltage (SV), and wire feed rate (WF) resulting into a best overall cutting performance. Analysis of variance (ANOVA) is also used to find out the significant effect of each machining parameter on the cutting performance. The analysis reported in this paper will be helpful for industry personnel to select the best set of process parameters for achieving a good result without the use of any software or statistical analysis

Multi-objective optimization of electro-discharge machining (EDM) parameter for sustainable machining

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Multi-objective optimization of electro-discharge machining (EDM) parameter for sustainable machining

In the present investigation, experiments have been planned using L9 orthogonal array to obtain optimal level combination of input process parameters such as current, pulse on time and voltage. A multi-objective optimization technique using Vikor Index has been used to optimize simultaneously the material removal rate, tool wear rate, surface roughness and radial overcut .The effects of various input process parameters on the overall performance of EDM have been studied using ANOVA Technique. Further, a mathematical correlation has been established between various input parameters with the individual output parameters using a multiple linear regression Analysis

Effect of Thermo-Physical Properties of the Tool Materials on the Electro-Discharge Machining Performance of Ti-6Al-4V and SS316 Work Piece Materials

Electro-discharge machining (EDM) is a useful non-conventional machining operation frequently applied to make different complex geometries in any conducting material. The objectives of the present paper are to study the effect of a variation of thermo-physical properties (TPP) of three different tool materials on EDM performances. The different performances compared in this paper are: material removal rate (MRR), tool-wear rate (TWR), surface roughness (SR), radial overcut (ROC), surface-crack density (SCD) and surface hardness. Two of the most widely used work piece materials, such as corrosion-resistant austenitic stainless steel (SS316) and high strength corrosion-resistance titanium alloy (Ti-6Al-4V), are machined with the help of three different tools by varying input current and maintaining constant pulse-on time, pulse-off time and flushing pressure. Microstructural studies of the tool tip surface after machining have also been carried out. It is found that among these three tool materials, the copper tool showed the best machining performance with respect to material removal rate, radial overcut, surface finish and surface-crack density. This work will help industry personnel to choose a suitable tool for a specific work piece material