Sie sind auf Seite 1von 4

Patel et al.

, International Journal of Advanced Engineering Technology E-ISSN


ISSN 0976
0976-3945

Research Paper

PARAMETRIC OPTIMIZATION OF WIRE CUT EDM MACHINE


ON HARD STEEL ALLOY WITH MULTIPLE QUALITY
CHARACTERISTICS
a

Atul J Patela, Prof.Satyam P Patelb


Address for Correspondence

PG Student, bAssistant Professor,, Department of Mechanical Engineering, S.P.B.Patel Engineering


College Linch, Mehsana, North Gujarat, 384435, India
ABSTRACT:
The objective of the present work is to investigate the effects of the various WEDM process parameters on the machining
quality and to obtain the optimal sets of process parameters so that the quality of machined parts can be optimized. The
working ranges and levels of the WEDM process parameters are found using one factor at a time approach. The Taguchi
technique has been used to investigate the effects of the WEDM Three levels of each of the factors wi
will be taken and
experiments is designed by Taguchi methodology. L9 Orthogonal Array are used and experiments
experiments will be performed as
designed by Taguchi method. Optimal levels of process parameters will be identified using Grey Relational Analysis and the
relatively significant parameters are determined by Analysis of Variance. The variation of output responses with process
parameters are mathematically modelled. Results of the experimentation will be analyzed MINITAB software analytically
as well as graphically using ANOVA and main effect-interaction
effect
plots, respectively
KEYWORDS: Grey-Taguchi
Taguchi method, WEDM, MRR, Surface roughness

1. INTRODUCTION:
Electrical discharge machining (EDM) is one of the
must extensively used nonconventional, thermo electric metal removal process which encodes
material from the work place by a series of discrete
spark between a work and a tool electrode immersed
in a liquid dielectric medium. Electrical energy is
used directly
y to cut the material in final shape.
Melting and vaporization takes place by theses
electrical discharges. The minute a mounts of the
work material is then ejected and flushed away by the
dielectric medium. The sparks occur at high
frequency which continuously
ously and effectively
removes the work prices material by melting and
evaporation. To initiate the machine process
electrode and work piece are separated by a small gap
known as spark gap which results into a pulsed
discharge causing the removal of material.
ial.
The dielectric acts as a deionizing medium between
two electrodes and its flow helps in vacating the
resoliclified debris to assure optimal conditions for
spark generation. In micro-wire
wire EDM operation the
work piece metal is cut with a special metal wire
w
electrode that is programmed to travel along a
definite path. Spark discharges and generated
between a small wire electrode and a work piece to
produce complex two dimensional and threethree
dimensional shapes according to a NC path. A very
thin wire in the range of 0.02 to 0.3 mm in diameter
as an electrode is used in the wire-cut
cut EDM. It
machines a work piece with electrical discharge like
a bands haw by moving either the work piece or the
wire. The mechanism of metal removal is same as in
connectional EDM
M The most prominent feature of a
moving wire is that a complicated cut can be early
machined without using a forming electrode The
CNC system of wire EDM has the duty to provide the
function of geometry trajectory, sequential control,
pulse generator control,
rol, wire feed and wire tension
control and machining process control.
The WEDM machine tool comprises of a main
worktable (X-Y)
Y) on which the work piece is
clamped; an auxiliary table (U-V)
V) and wire drive
mechanism. The main table moves along X and YY
axis and it is driven by the D.C servo motors. The
travelling wire is continuously fed from wire feed
spool and collected on take up spool which moves
IJAET/Vol. IV/ Issue II/April-June, 2013/74--77

though the work piece and is supported under tension


betweenn a pair of wire guides located at the opposite
sides of the work piece. The lower wire guide is
stationary where as the upper wire guide, supported
by the U-V
V table, can be displaced transversely along
U and V-axis
axis with respect to lower wire guide. The
upper
per wire guide can also be positioned vertically
along Z-axis by moving the quill.

Fig 1.1 Schematic diagram of the WEDM process

2 EXPERIMENTAL METHODOLOGY
2.1 Taguchi design approach
Taguchiss comprehensive system of quality
engineering is one of the greatest engineering
achievements of the 20th century. His methods focus
on the effective application of engineering strategies
rather than advanced statistical.
Step 1: In this step, the original response values are
transformed into S/N ratio values. Further analysis is
carried out based on these S/N ratio values. The
material removal rate is a higher
higher-the-better
performance characteristics, since the maximization
of the quality characteristic of interest is sought and
can be expressed as:

S
1
1
Ratio for MRR  10log 10
10 n  
N
y


The surface roughness is the lower-the


the-better
performance characteristic and the loss function for
the same can be expressed as

S
1
Ratio for Ra  10log 10
10 n  y2
N


preStep 2: In the grey relational analysis, a data pre


processing is first performed in order to normalize
the raw data for analysis. Normalization is a
transformation performed on a single data input to
distribute the data evenly and scale it into an
acceptable range for further analysis. In this study, a

Patel et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

linear normalization of the S/N ratio is performed in


the range between zero and unity, which is also
called the grey relational generating. yij is
normalized as Zij (0Zij1) by the following formula
to avoid the effect of adopting different units and to
reduce the variability. The normalized material
removal rate corresponding to the larger-the-better
criterion can be expressed as:
max #  #
 
max #  min #
The surface roughness should follow the lower-thebetter criterion and can be expressed as:
max #  #
 
max #  min #
Step 3: The grey relational coefficient is calculated
to express the relationship between the ideal (best)
and actual normalized experimental results. The grey
relational coefficient can be expressed as:
%& ( )%*+
$ 
 ( )%*+
Where;
j=1,2...n; k = 1,2...m, n is the number of experimental
data items and m is the number of responses.
Where is the distinguishing coefficient, which is
defined in the range 0 1. The WEDM process
parameters are equally weighted in this study, and
therefore is 0.5.
Step 4: The grey relational grade is determined by
averaging
the
grey
relational
coefficient
corresponding to each performance characteristic.
The overall performance characteristic of the
multiple response process depends on the calculated
grey relational grade. The grey relational coefficient
can be expressed as:
,
1
#   $
&

electrode material used was a 0.25 mm diameter


brass wire. A small gap of 0.025 mm to 0.05 mm is
maintained in between the wire and work-piece .
Table shows the nine cutting experimental runs with
the assigned levels of the process parameters
according to the selected L9 orthogonal layout.
3.1 Work Piece Material:
AISI 304 stainless steel
Material thickness is 10 mm.
Table 3 Chemical compositions

Table 3.1 Data obtained from experimental work for


WEDM process

In the grey relational analysis, a data pre-processing


is first performed in order to normalize the raw data
for analysis. Normalization is a transformation
performed on a single data input to distribute the data
evenly and scale it into an acceptable range for
further analysis. In this study, a linear normalization
of the S/N ratio is performed in the range between
zero and unity, which is also called the grey
relational generating.
Table 3.2 Normalized S/N value of SR and MRR

-

Where grey relational grade for the jth experiment


and k is the number of performance characteristics.
2.2 Factors and their levels in WEDM PROCESS:
Table 2 Factors and their levels in WEDM Process

3 SELECTION OF MACHINE TOOL


The experiments will be carried out on a wire-cut
EDM machine (ELEKTRONICA SPRINTCUT
MACHINE TOOL] installed at SHAKTI WIRE
CUT, ODHAV AHMEDABAB-3800026.

Figure 2.1: Pictorial View of WEDM Machine Tool

The experiments were carried out on a Four-axes


Electronica Supercut CNC WEDM machine. The
IJAET/Vol. IV/ Issue II/April-June, 2013/74-77

The grey relational coefficient is calculated to


express the relationship between the ideal (best) and
actual normalized experimental results.
Table 3.3 GRC value of SR and MRR

The grey relational grade is determined by averaging


the grey relational coefficient corresponding to each
performance characteristic. The overall performance
characteristic of the multiple response process
depends on the calculated grey relational grade.
This approach converts a multiple response process
optimization problem into a single response

Patel et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

optimization situation with the objective function of


an overall grey relational grade. Table shows the grey
relation coefficient and grey relational grade for each
experiment using the L9 orthogonal array. The higher
grey relational grade reveals that the corresponding
experimental result is closer to the ideally normalized
value. Experiment 7 has the best multiple
performance characteristic among 9 experiments,
because it
has the highest grey relational grade
shown in Table.
Table 3.4 GRG calculation value
Figure 3.3: Main effect plot of Material removal rate
(MRR)

Since the experimental design is orthogonal, it is


possible to separate out the effect of each machining
parameter on the grey relational grade at different
levels.
The mean of the grey relational grade for each level
of the other machining parameters can be computed
in a similar manner. The mean of the grey relational
grade for each level of the machining parameters is
summarized and shown in graph.

Figure 3.4: Effect of Process Parameters on MRR (S/N


Data)
Table 3.6 ANOVA for Material Removal Rate

Figure 3.1: Num of Expriments vs GRG

Taguchi Analysis: Ra(m) versus ton, toff, wt, ip


Response Table for Signal to Noise Ratios
Smaller is better
Table 3.7 Response Table for S/N Data

Figure 3.2: Main effect plot of GRG for WEDM Process

Taguchi Analysis: MRR(mm3/min) versus ton,


toff, wt, ip
Response Table for Signal to Noise Ratios (Larger
is better)
Table 3.5: Response Table for S/N Data

Figure 3.5: Main effect plot of Surface Roughness (Ra)

IJAET/Vol. IV/ Issue II/April-June, 2013/74-77

Patel et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Figure 3.6: Effect of Process Parameters on Surface


roughness for (S/N Data)
Table 3.8 ANOVA for Surface roughness

time, value of material removal rate is


increase.
From the ANOVA and also SN ratio
response table it is conclude that the Pulse
on time and Input power is most significant
parameter which contributes more to MRR.

From ANOVA analysis the percentage


contribution of Pulse on time is 63.67%,
pulse off time of 2.44% and wire tension of
1.80 %, and Input power 31.66 % on MRR.
relations
between the
Mathematical
machining parameters, namely Pulse Ontime, Pulse Off-time, Wire tension and input
power and performance characteristics such
as MRR and Ra are established by the linear
regression analysis method by using
MINITAB software.
REFERENCES:
1.

2.

3.

4 REGRESSION ANALYSIS EQUATIONS:


By use of MINITAB 16 software I found the
regression analysis equation.
Regression analysis of Material removal rate for
WEDM Process
Regression Equation:
MRR = - 50.8 + 0.786 Pulse on time - 0.302 Pulse off
time - 0.005 Wire tension + 0.0639 Input power
Regression analysis of Surface roughness for WEDM
Process
Regression Equation:
Ra = - 3.66 + 0.0493 Pulse on time - 0.0043 Pulse off
time + 0.0096 Wire tension + 0.00203 Input power

5 RESULTS AND CONCLUSION:


In this dissertation work, various cutting parameters
like pulse on time, Pulse of time, Wire tension, and
input power have been evaluated to investigate their
influence on surface roughness and material removal
rate. Based on the result obtained, it can be concluded
as follows:
 Surface roughness
Pulse on time, Input power, pulse off time
and wire tension significantly effects on
surface roughness.
Input power is found to have effect on
surface roughness. Increase in Input power,
value of surface roughness is increase.
Pulse off time is found to have effect on
surface roughness. Increase in pulse off time
value of surface roughness is decrease.

From ANOVA analysis the percentage


contribution of Pulse on time is 52.21%,
pulse off time of 10.86% and wire tension of
8.12%, and Input power 26.96 % on surface
roughness.
 Material removal rate
Pulse on time, Input power, pulse off time
and wire tension significantly effects on
MRR.
Pulse on time is found to have effect on
material removal rate. Increase in Pulse on
IJAET/Vol. IV/ Issue II/April-June, 2013/74-77

4.

5.

6.

7.

8.

9.

S. S.Mahapatra and Amar Patnaik et al Parametric


Optimization of WireElectrical Discharge Machining
(WEDM) Process using Taguchi Method Paper
accepted July, 2005. Technical Editor: Anselmo
Eduardo Diniz Vol. XXVIII, No. 4, October-December
2006
I Menzies, P. Koshy et al.Assessment of abrasionassisted material removal in wire EDM CIRP Annals Manufacturing Technology 57 (2008) 195198
Gautam kocher, Karan Chopra et al Investigation of
Surface integrity of AISI D3 tool steelAfter EDM
International Journal of Emerging Technology and
Advanced Engineering, ISSN 2250-2459, Volume 2,
Issue 4, April 2012
Ahmet Hascalyk, Ulas Caydas et al Experimental
study of wire electrical discharge machining of AISI D5
tool steel Journal of Materials Processing Technology
148 (2004) 362367
J.A. Sanchez, J.L. Rodil, A. Herrero et al On the
influence of cutting speed limitation on the accuracy of
wire-EDM corner-cutting Journal of Materials
Processing Technology 182 (2007) 574579
Goswami Amitesh, Kumar Jatinder et al An
investigation into the machining characteristics of
Nimonic 80A using cnc wire edm International
Journal of Advanced Engineering Technology E-ISSN
0976-3945
Mohd Amri Lajis et al The Implementation of Taguchi
Method on EDM Process of Tungsten Carbide
European Journal of Scientific Research ISSN 1450216X Vol.26 No.4 (2009), pp.609-617
Sagbas and F. Kahraman et al Prediction of surface
roughness in wire electrical discharge machining using
design of experiments and neural networks Iranian
Journal of Science & Technology, Transaction B,
Engineering, Vol. 33, No. B3, pp 231-240
Pujari Srinivasa Rao et al. Effect of wedm conditions
on surface roughness: a prapmetric optimization using
taguchi method International journal of advanced
engineering sciences and technologies vol no. 6, issue
no. 1, 041 - 048

Das könnte Ihnen auch gefallen