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#1
Final Year Student, School of M echanical Engineering, KIIT University , Bhubaneswar, Odisha, India
#2
Professor, School of M echanical Engineering, KIIT University, Bhubaneswar, Odisha, India
In the present study, D2 steel is machined in die sink electro-discharge machine with
electrolytic copper and bronze tool to anal yze the machining characteristic. The process
parameters such as pulse on ti me (Ton), pulse off ti me (Tof f ) and peak current (Ip) are
taken as the input variables whereas metal removal rate (MRR) and surface roughness
(SR) are chosen response variables. The experi mentation was conducted using Taguchi’s
L9 orthog onal array with di fferent combi nation of process parameters. The signal to
noise (S/N) ratio of each experimental data has been found to correlate the input
vari ables with res ponse variables. Also Analysis of Variance (ANOVA) techni que is used
to check the significance of the model and confirmati on test is conducted to compare the
experi mental data with the predicted data to i dentify the effecti veness of the proposed
method. Furthermore, from the ANOVA result, it is found that peak current is the most
significant parameter among the other for material removal rate. The correlation
coefficient R-sq value found to be 0.9 which is very much close to 1 which shows the
adequacy of model is quite g ood enough. Si milarly, analysis for surface roughness has
been carried out and it is found that pulse on ti me is most significant parameter for
surface roughness. The main effect pl ots for both the res ponse variables have been
analyzed and it has been found the results are good agreement with ANOVA result.
Keywords — MRR, Surface Roughness, ANOVA
B. Electrode selected
MATERIAL REM OVAL RATE AND SURFACE ANALYSIS OF VA RIA NCE FOR MATERIA L
ROUGHNESS FOR COPPER TOOL REM OVA L RATE FOR COPPER TOOL
MRR Ra Source DF Adj SS Adj MS F P
Sl. No Ip Ton Toff (g/min) (avg ) Ip 2 0.003864 0.0019318 137.56 0.007
1 4 300 4 0.009589 4.08 Ton 2 3.46E-05 0.0000173 1.23 0.448
2 4 500 6 0.009183 3.64 Toff 2 8.98E-05 0.0000449 3.2 0.238
3 4 750 8 0.010563 2.62 Error 2 2.81E-05 0.000014
4 6 300 6 0.020000 5.39 Total 8
5 6 500 8 0.019354 5.31
R-sq value=99.30% and R-sq(Adj) =97.2%
6 6 750 4 0.005882 2.55
Since P value fo r Ip is less than 0.05 and its rank is
7 8 300 8 0.058750 7.50 determined to be 1, it is taken to be statistically significant.
8 8 500 4 0.052173 5.87
9 8 750 6 0.057500 3.23
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TABLE VI The combination of the levels corresponding to the largest
MEAN RESPONSE TABLE FOR MATERIA L values of SN ratios form the optimu m parameter
REM OVA L RATE FOR COPPER TOOL combination for better response. From the main effects plot
Level Ip Ton Toff for SN Rat ios of MRR using copper tool we see that 3rd
level of Ip , 1st level of Ton and 3rd level of Toff is the optimu m
1 0.009779 0.029446 0.022548 combination of parameters for maximu m MRR.
2 0.015079 0.026904 0.028895
3 0.056141 0.024649 0.029556
Delta 0.046363 0.004798 0.007008
Rank 1 3 2
TABLE VII
ANALYSIS OF VA RIA NCE FOR SURFACE
ROUGHNESS FOR COPPER TOOL
Source DF Adj SS Adj MS F P
Ip 2 6.542 3.271 21.27 0.045
Ton 2 13.2538 6.6269 43.08 0.023
Toff 2 2.0768 1.0384 6.75 0.129
Error 2 0.3076 0.1538
Fig 4 S/N ratio graph for surface roughness on copper
Total 8 tool
R-sq value=98.61% and R-sq(Adj) =94.45% Fro m the main effects plot for SN Ratios of Surface
Since P value fo r Ip is less than 0.05 and its rank is Roughness using copper tool we see that 1st level of Ip , 3rd
determined to be 1, it is taken to be statistically significant. level of Ton and 1st level of Toff is the optimu m co mbination
of parameters for min imu m Ra.
TABLE VIII The R2 value obtained using bronze tool for MRR and Ra are
MEAN RESPONSE TABLE FOR SURFACE 0.9595 and 0.9921 respectively thus showing that the R2
ROUGHNESS ON COPPER TOOL value is very much close to 1 which is desirable.
Level Ip Ton Toff
TABLE IX
1 3.447 5.657 4.167
2 4.417 4.94 4.087 ANALYSIS OF VA RIA NCE FOR MATERIA L
3 5.533 2.8 5.143 REM OVA L RATE ON BRONZE TOOL
Delta 2.087 2.857 1.057 Source DF Adj SS Adj MS F P
Rank 2 1 3 Ip 2 0.0042592 0.00213 23.27 0.041
Ton 2 0.0000601 3.01E-05 0.33 0.753
Toff 2 0.0000197 9.8E-06 0.11 0.903
Error 2 0.000183 9.15E-05
Total 8
REFERENCES