Abstract

In the present trend of technological development, micro-machining

is gaining popularity in the miniaturization of industrial products. In
this work, a hybrid process of micro-wire electrical discharge
grinding and micro-electrical discharge machining (EDM) is used in
order to minimize inaccuracies due to clamping and damage during
transfer of electrodes. The adaptive neuro-fuzzy inference system
(ANFIS) and back propagation (BP)-based artificial neural network
(ANN) models have been developed for the prediction of multiple
quality responses in micro-EDM operations. Feed rate, capacitance,
gap voltage, and threshold values were taken as the input
parameters and metal removal rate, surface roughness and tool
wear ratio as the output parameters. The results obtained from the
ANFIS and the BP-based ANN models were compared with
observed values. It is found that the predicted values of the
responses are in good agreement with the experimental values and
it is also observed that the ANFIS model outperforms BP-based
ANN.

Application of Taguchi, ANFIS and grey relational analysis for studying,

modeling and optimization of wire EDM process while using gaseous media

In the dry wire electrical discharge machining (WEDM) process, the liquid dielectric
is replaced with gaseous medium to enhance the machining environment safety.
Also, this modification improves the surface quality of machined specimen but
decreases the material removal rate of the process. In the present work,
experimental study of dry WEDM process has been performed while machining of
Al/SiC metal matrix composite. At first, a series of exploratory experiments has been

conducted to identify appropriate gas and wire material based on their cutting
velocity. After selection of the best gas and best wire, they were used for later stage
of experiments. At the next stage, experiment were designed and conducted based
on L27 Taguchi's orthogonal array to study the effect of pulse on time, pulse off time,
gap voltage, discharge current, wire tension and wire feed on cutting velocity (CV)
and surface roughness (SR). Analysis of variances (ANOVA) has been performed to
identify significant factors. In order to correlate relationship between process inputs
and responses, adaptive neuro-fuzzy inference system has been utilized. At the end,
a grey relational analysis has been used to maximize CV and minimize SR
simultaneously. Results indicated that oxygen gas and brass wire guarantee
superior cutting velocity. Also according to ANOVA, pulse on time and current were
found to have significant effect on CV and SR.

An adaptive neuro-fuzzy inference system (ANFIS) model for

wire-EDM
A wire electrical discharge machined (WEDM) surface is characterized by its roughness and
metallographic properties. Surface roughness and white layer thickness (WLT) are the main
indicators of quality of a component for WEDM. In this paper an adaptive neuro-fuzzy inference
system (ANFIS) model has been developed for the prediction of the white layer thickness (WLT)
and the average surface roughness achieved as a function of the process parameters. Pulse
duration, open circuit voltage, dielectric flushing pressure and wire feed rate were taken as
models input features. The model combined modeling function of fuzzy inference with the
learning ability of artificial neural network; and a set of rules has been generated directly from
the experimental data. The models predictions were compared with experimental results for
verifying the approach.

Multi-objective optimization of material removal rate and surface roughness in

wire electrical discharge turning

Abstract

Wire electrical discharge turning (WEDT) is an emerging area, and

it can be used to generate cylindrical forms on difficult to machine
materials by adding a rotary axes to WEDM. The selection of
optimum cutting parameters in WEDT is an important step to
achieve high productivity while making sure that there is no wire

breakage. In the present work, the WEDT process is modelled using

an artificial neural network with feed-forward back-propagation
algorithm and using adaptive neuro-fuzzy inference system. The
experiments were designed based on Taguchi design of
experiments to train the neural network and to test its performance.
The process is optimized considering the two output process
parameters, material removal rate, and surface roughness, which
are important for increasing the productivity and quality of the
products. Since the output parameters are conflicting in nature, a
multi-objective optimization method based on non-dominated
sorting genetic algorithm-II is used to optimize the process. A
pareto-optimal front leading to the set of optimal solutions for
material removal rate and surface roughness is obtained using the
proposed algorithms. The results are verified with experiments, and
it is found to improve the performance of WEDT process. Using this
set of solutions, required input parameters can be selected to
achieve higher material removal rate and good surface finish.

An intelligent and automated system for EDM hole drilling of super alloys
This paper introduces an intelligent and automated system proposed for EDM hole drilling of super-alloys in
manufacturing and re-manufacturing stages of products used in aerospace, die/mold and medical surgery. The
system is a user-friendly computer-based program, which guides the end-user in order to perform sustainable and
effective process. To accomplish the goals of the work, a well-planned workshop tests have been performed via
drilling of micro and macro-scale holes (0.4-3 mm) on Ti-6AI-4V and Inconel 718 alloys, which are commonly used in
aerospace industry and medical sector for manufacturing of highly critical components. The experimental data was
refined and analysed using ANOVA to obtain parameter's relations and mathematical modelling for optimisation.
ANFIS has been adopted to correlate the EDM hole drilling parameters (i.e. pulse current, pulse duration/interval,
capacitance, material removal rate, electrode wear and surface roughness) for fulfilling reliable, cost/time effective
and efficient hole making operations.

Application of adaptive neuro-fuzzy inference system and cuckoo optimization

algorithm for analyzing electro chemical machining process

Electrochemical machining process (ECM) is increasing its importance due to some

of the specific advantages which can be exploited during machining operation. The
process offers several special privileges such as higher machining rate, better
accuracy and control, and wider range of materials that can be machined.
Contribution of too many predominate parameters in the process, makes its
prediction and selection of optimal values really complex, especially while the
process is programmized for machining of hard materials. In the present work in
order to investigate effects of electrolyte concentration, electrolyte flow rate, applied
voltage and feed rate on material removal rate (MRR) and surface roughness (SR)
the adaptive neuro-fuzzy inference systems (ANFIS) have been used for creation
predictive models based on experimental observations. Then the ANFIS 3D surfaces
have been plotted for analyzing effects of process parameters on MRR and SR.
Finally, the cuckoo optimization algorithm (COA) was used for selection solutions in
which the process reaches maximum material removal rate and minimum surface
roughness simultaneously. Results indicated that the ANFIS technique has
superiority in modeling of MRR and SR with high prediction accuracy. Also, results
obtained while applying of COA have been compared with those derived from
confirmatory experiments which validate the applicability and suitability of the
proposed techniques in enhancing the performance of ECM process.