Parametric Optimization of Tool Wear Rate (TWR) On Die Sinking EDM by Using Taguchi and Anova

IDL - International Digital Library Of
Technology & Research

Volume 1, Issue 5, May 2017 Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
Parametric Optimization of Tool Wear Rate

(Twr) on
Die Sinking EDM by Using Taguchi and
Anova
M. Ramadas 1 , Dr.J.S.Soni2 , Dr.T. Vijaya Babu3
1
Associate Professor , Nishitha College of Engineering and Technology ,Lemoor (V), Hyderabad ,India
2
Professor Bharat Institute of Engineering and Technology , Ibrahimpatnam , Hyderabad ,India
3
Professor , Department of Mechanical Engineering, Vardhaman College of Engineering , Shamshabad , Hyderabad
1
das.7442012@gmail.com, 3 tirividhivijaybabu@gmail.com
Abstract: Electric Discharge Machining (EDM) is the electrical energy and turns it into thermal energy
through a series of discrete electrical discharges
a unconventional machining process where intricate
occurring between the electrode and work piece
and complex shapes can be machined. Only
immersed in an insulating dielectric fluid . Electrical
electrically conductive materials can be machined by
Discharge Machining (EDM) is a process of material
this process. These materials are being widely used in
removal using an accurately controlled electrical
die and mould making industries, aerospace,
discharge (spark) through a small gap (approximately
aeronautics and nuclear industries. In this work DIN
10 to 50 microns) filled with dielectric fluid between
1.2714 steel is the material used for the machining
an electrode and a work piece. The hardness of the
purpose and Copper is used as an electrode. In this
work piece has no effect on the process. Electrically
process Taguchi approach is used to create L27
conductive material is removed by controlled erosion
orthogonal matrix. Experiments were conducted with
through a series of electric sparks of short duration and
the L27 orthogonal array based on the Taguchi
high current density between the electrode and the
method. Moreover, the signal-to-noise ratios
work piece, both the work piece and tool is submerged
associated with the observed values in the experiments
in a dielectric bath, containing kerosene or distilled
were determined. The purpose of ANOVA to see the
water. During this process thousands of sparks per
individual effect of control factors on MRR and TWR.
second are generated, and each spark produces a tiny
In the present work, Optimization of TWR on EDM
crater in the material along the cutting path by melting
conducted by using Taguchi and ANOVA.
and vaporization. The objective of the present work is
Keywords: Die sinking EDM machine, tool wear rate,
to find a suitable process parameters to minimize the
Taguchis method, ANOVA
tool wear rate using DIN 1.2714 as a work piece steel
and square copper electrode as a tool and dielectric
1. INTRODUCTION
flushing. The machining parameter selected are
Electrical-discharge machining (EDM) is an
discharge current, pulse on time ,pulse off time ,
unconventional, non-contact machining process where
voltage , fluid pressure of the tool using Taguchi
metal removal is based on thermo-electric principles.
design approach analyzing the responses of EWR.
In this process, the material removal mechanism uses
The Taguchis method is used to formulate the
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experimental layout, ANOVA method is used to Taguchis method is a powerful technique for the
analysis the effect of process parameters on the design of a high quality system. It provides not
machining characteristics and find the optimal process only,an efficient but also a systematic approach to
parameters of Electric Discharge Machining. optimize designs for performance and quality.
2. LITERATURE SURVEY Furthermore, Taguchi parameter design can
reduce the fluctuation of system performance.
Soni and Chakraverti (1997) compared the
A. This experiment is governed by the following
various performance measures of rotating
steps are:
electrode with the stationary electrode. The
Select process parameters to be evaluated.
results concluded an improvement in MRR due
Select the appropriate orthogonal array
to the better flushing action and sparking
and assign these parameters to the
efficiency with little TWR but the surface finish
orthogonal array.
was improved.
Perform the experiments based on the
Soni & Chakraverti (1994) introduced rotary
arrangement of the orthogonal array.
disc for grooving operation on titanium alloy.
Analyze the experimental results using
The rotary electrode was placed above the work
the signal to noise(S/N) ratio and
material. The difficulty of debris problem was
analysis of variance (ANOVA).
encountered removal rate and arching occurs
due to the accumulation of debris particle
between the electrode and work piece. B. Experimental design
1) Step1- Process parameters selection: Process
Zhang et al. (1997) Spark erosion with
parameters and their ranges were determined by
ultrasonic frequency using a DC power supply
the research paper. The parameters are identified
instead of the usual pulse power supply. The
for the test such as current, pulse-on time, pulse
pulse discharge is produced by the relative
off time, flushing pressure, gap voltage.
motion between the tool and work piece
2) Step 2- Orthogonal array selection: To select
simplifying the equipment and reducing its cost.
an appropriate orthogonal array for the
It is easy to produce a combined technology
experiments, on the basis of parameter selection
which benefits from the virtues of USM and
and its levels. Here we have five parameters and
EDM.
three levels are selected.
Khanra et al. attempted to develop a ZrB2-Cu
3) Step 3- Conduct the experiment and
composite that can be used as an EDM tool.
Recording of responses:
They tested the tool by determination of
Twenty seven experimental runs were conducted
responses like Material Removal Rate (MRR),
as per the Taguchis L27 orthogonal array. The
Tool Wear Rate (TWR), Surface Roughness
test runs were carried out at random to avoid a
(SR) .
systematic error creeping into the experimental
Nipanikar optimized the process parameters of
procedure.
EDM by using Taguchi method. Optimization
4) Step 4- Analysis using ANOVA: The analysis
was carried out by taking into account the
of variance (ANOVA) is used to discuss the
responses which include material removal rate
relative importance of all control factors on the
MRR, TWR .
machined material quality and also to determine
which control factor has the most significant
3. METHODOLOGY effect. Analysis of variance (ANOVA) is
employed to find the optimal process parameter
levels and to analyze the effect of these


parameters on metal removal rate values and electronic balance.
electrode wear rate. B. Selection of work piece
DIN 1.2714 steel is an important tool and dies
4. EXPERIMENTAL SETUP material, mainly because of its high strength, high
hardness, and high wear resistance. It has a high
The experiments were conducted using the Electric
strength due to that it cannot be easily machinable by
Discharge Machine, model ELECTRONICA -
conventional machining techniques. EDM is a
ELECTRAPLUS PS 50ZNC (die sinking type) .The
nonconventional machining process that removes
EDM consists of the following parts Dielectric
material by thermal erosion, such as melting and
reservoir, pump and circulation system, power
vaporization of material. To understand the
generator and control unit ,working tank with work
machining characteristics of DIN 1.2714 steel by
holding device , X-Y working table , the tool holder,
EDM is explored in this experimental study. DIN
the servo system for feeding the tool. Before
1.2714 steel material is used in extrusion die, hot
experimentation, the work piece top and bottom
forging tools, dies for processing tin ,lead and zinc
faces were ground to a good surface finish using a
alloys. It is chemically composed of approximately
surface grinding machine .The work piece was held
0.59 percent carbon, .83 percent manganese, 1.13
on the machine table using a specially designed
percent chromium, silicon 0.28, phosphorus
fixture as shown in fig1
0.013,nickel 1.58, molybdenum 0.46and 0.7 percent
vanadium. The hardening temperature of DIN 1.2714
steel is between 870 degrees Celsius and 900 degrees
Celsius. DIN 1.2714 is a high carbon Alloy steel
which achieves a high degree of hardness with
compressive strength and abrasion resistance.
5. TAGUCHI DESIGN
Taguchi Method was proposed by Dr. G. Taguchi
in the year 1950. Signal represents the effect on
the average response while the noise is a measure
of the influence on the deviation from the average
response. The S/N ratio is the ratio of the mean
(Signal) to the standard deviation (Noise). This
Fig 1: Die sinking EDM ratio helps to identify the optimum level of
The work piece and tool were connected to the process parameters. A high S/N ratio is desirable
negative and positive terminals of the power supply, as the signal level is much higher than the random
respectively. The dielectric fluid used here is noise level that leads to best performance. The
kerosene. The time taken for machining was calculation of S/N ratio depends on the quality
recorded. The experiments were conducted in the characteristics of the product or process to be
order of L27 orthogonal array. At the end of each optimized. The equation for calculating S/N ratios
experiment, the work piece was removed from the for larger is better and smaller is better .In the
machine, washed, dried and weighed on an study, a three factor mixed level setup is chosen


with a total of twenty seven numbers of
experiments to be conducted and hence the L27 50 15 90 150 0.5 0.0032 49.88
was chosen.
Table1 : Response parameter and control 50 15 90 150 0.75 0.0048 46.21
parameters with their levels
60 9 45 150 0.25 0.0004 67.6
Levels
Control parameters 1 2 3 60 9 45 150 0.5 0.0004 66.3
Gap voltage (A) 50 60 70 60 9 45 150 0.75 0.0005 65.94
Discharge current
9 12 15
(A) 60 12 90 90 0.25 0.0044 46.93
Pulse off time (s) 15 45 90
60 12 90 90 0.5 0.0046 46.66
Pulse on time (s) 90 120 150
Fluid pressure 60 12 90 90 0.75 0.0045 46.83
0.25 0.50 0.75
(kg/cm2)
60 15 15 120 0.25 0.0046 46.72
6.RESULT AND DISCUSSIONS 60 15 15 120 0.5 0.005 45.93

In the study. This experiment has 5 variables at 3
different settings. We conducted a Taguchi 60 15 15 120 0.75 0.0062 44.1
experiment with a L27 orthogonal array
(27tests,5variables, 3 levels) and calculate S/N ratios 70 9 90 120 0.25 0.0006 64.02
corresponding to each experiment. The experiment
70 9 90 120 0.5 0.0007 62.31
design is shown in table 2.
70 9 90 120 0.75 0.0008 61.51
Table 2. Response table for EWR
70 12 15 150 0.25 0.0012 57.83
P P flushing S/N
GV PC TWR
off on pressure Ratio
70 12 15 150 0.5 0.0013 57.38
50 9 15 90 0.25 0.0018 54.47
70 12 15 150 0.75 0.0013 57.26
50 9 15 90 0.5 0.0016 55.56
70 15 45 90 0.25 0.0096 40.27
50 9 15 90 0.75 0.0016 55.41
70 15 45 90 0.5 0.0098 40.14
50 12 45 120 0.25 0.002 53.8
70 15 45 90 0.5 0.0098 40.09
50 12 45 120 0.5 0.0042 47.37
The S/N ratios for EWR are calculated as given in
50 12 45 120 0.75 0.0034 49.3 Equation.1. Taguchi method is used to analysis the
result of response of machining parameter for smaller
50 15 90 150 0.25 0.0027 51.08 is better criteria .For smaller is better.
S/N = -10 *log((Y2)/n) (1)


Where, yi = experimental value in the ith , n =number
of replications .Where the S/N ratios
calculated from observed values, yi represents the
experimentally observed value of the ith experiment
and n=1 is the repeated number of each experiment in
L-27 is conducted.
Table 2: S/N Ratio table for EWR

flushing
Level GV PC Poff Pon pressure
1 51.45 61.46 52.74 48.28 53.64

2 53.00 51.48 53.84 52.78 52.39
3 55.09 45.54 52.83 57.72 53.32
Delta 3.63 15.92 1.10 9.44 1.25
Rank 3 1 5 2 4
Table 3: Analysis of variance for S/N ratio

Source DF Adj SS Adj MS F-Value P-Value Fig 3: Residual plots for S/N ratio
GV 2 18.17 9.083 5.14 0.019

PC 2 1242.49 621.247 351.70 0.000
Poff 2 1.80 0.900 0.51 0.610
Pon 2 482.72 241.358 136.64 0.000
flushing pr 2 15.74 7.872 4.46 0.029
Error 16 28.26 1.766
Lack-of-Fit 15 28.26 1.884 1507.29 0.020
Pure Error 1 0.00 0.001
Total 26 1792.83
Fig 4: Interaction plot for S/N ratio
Fig 2: Main effect plot for S/N ratios (EWR)


[2] Nipanikar, Parameter Optimization of Electro
Discharge Machining of AISI D3 Steel Material by
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Machining of Al/Al2O3 MMC by Rotary EDM,
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current (15A),voltage (70V), pulse on time(150),pulse
off time(90) and flushing pressure(0.25kg/cm2) to
obtain maximum EWR
8. REFERENCES
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Parametric Optimization of Tool Wear Rate (TWR) On Die Sinking EDM by Using Taguchi and Anova

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International e-Journal For Technology And Research-2017