Analysis and Multi-objective Optimisation of Surface Modification Phenomenon by EDM Process with Copper-Tungsten Semi-sintered P/M Composite Electrodes

H. S. Sidhu^1, and S. S. Banwait²

¹Mechanical Engineering, SBAS Government Polytechnic College, Badbar, India

²Mechanical Engineering, National Institute of Technical Teachers Training and Research, Chandigarh, India

Cite this paper:
H. S. Sidhu and S. S. Banwait. Analysis and Multi-objective Optimisation of Surface Modification Phenomenon by EDM Process with Copper-Tungsten Semi-sintered P/M Composite Electrodes. American Journal of Mechanical Engineering. 2014; 2(5):130-142. doi: 10.12691/ajme-2-5-2

Abstract

In the present experimentation work, attempts have been made to model, analyse and optimise the surface modification phenomenon in electrical discharge machining process using response surface methodology. The central composite second order rotatable design has been chosen for designing the experiments and response surface methodology was applied for developing the mathematical models. Efforts has been made to correlate the four input process parameters; peak discharge current, pulse-on time, pulse-off time and tool electrode powder compaction pressure with two output responses; surface deposition rate and surface roughness. Results obtained were presented in the form of three dimensional surface plots. Analysis of variance had been performed to check the adequacy of the developed mathematical models as well as significance of each term comprising the models. Statistical software was used to construct the plots to analyse the influence of individual input process parameter on output responses. Composite desirability function approach was used for multi-objective optimisation of the developed models. Optimal parameter combinations for achieving maximum surface deposition rate and minimum surface roughness have been observed and presented in the form of contour plots. The optimal predicted results were experimentally verified, matched well with the predicted results.

Keywords:
electrical discharge machining response surface methodology analysis of variances surface deposition rate surface roughness design of experiment

This work is licensed under a Creative Commons Attribution 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/

Figures

References:

[1]	Erden, A., “Effect of materials on the mechanism of electrical discharge machining (EDM),” J Engg Material Technology, 105 (2), 132-138. April, 1983.
[2]	Chen, S.L., Yan, B.H. and Huang, F.Y., “Influence of kerosene and distilled water as dielectrics on the electric discharge machining characteristics of Ti-6Al-4V,” Journal of Materials Processing Technology, 87, 107-111.March, 1999.
[3]	Ming, Q.Y., Ming, Q.Y. and He L.Y., “Powder-suspension dielectric fluid for EDM,” J Material Processing Technology, 52(1), 44-54.May, 1995.
[4]	Yan, B.H., Lin, Y.C., Huang, F.Y. and Wang, C.H., “Surface modification of SKD 61 during EDM with metal powder in the dielectric,” Materials Trans JIM 42(12), 2597-2604. 2001.
[5]	Kruth, J. P., Stevens, L., Froyen, L. and Lauwers, B., “Study of the white layer of a surface machined by die sinking electro discharge machining,” Ann CIRP 44(1), 169-172. January, 1995.
[6]	Jeswani, M.L., “Dimensional analyses of tool wear in electrical discharge machining,” Wear, 55, 153-161. July, 1979.
[7]	Wang, P.J. and Tsai, K.M., “Semi-empirical model on work removal and tool wear in electrical discharge machining,” Journal of Materials Processing Technology, 114, 1-17. July, 2001.
[8]	Cogun, C., Kocabas, B. and Zgedik, A.O., “Experimental and theoretical investigation of workpiece surface profiles in electrical discharge machining,” Journal of the Faculty of Engineering and Architecture, Gazi University, 19, 97-106.
[9]	Gopal, I. and Rajurkar, K.P., “Artificial Neural Network approach in modeling of EDM process,” Intelligent Engineering Systems through Artificial Neural Networks, 2, 845-850.1992.
[10]	Tsai, K.M. and Wang, P. J., “Comparisons of neural network models on material removal rate in electrical discharge machining,” Journal of Materials Processing Technology, 17, 111-112. Nov, 2001.
[11]	Kesheng, W., Gelgele, H.L., Wang, Y., Yuan, Q. and Fang, M., “A hybrid intelligent method for modeling the EDM process,” International Journal of Machine Tools & Manufacture, 43(10), 995-999. 2003.
[12]	Mandal, D., Pal Surjya, K. and Saha, P., “Modeling of electrical discharge machining process using back propagation neural network and multi-objective optimization using non-dominating sorting genetic algorithm-II,” Journal of Materials Processing Technology, 186(1-3), 154-162. May, 2007.
[13]	Rao, G.K.M., RangaJanardhana, G., HanumanthaRao, D. and SriniwasRao, M., “Development of hybrid model and optimization of metal removal rate in electric discharge machining using artificial neural network and genetic algorithm,” ARPN Journal of Engineering and Applied Science, 3(1), 19-30. 2008.
[14]	Lin, C.L., Lin, J.L., and Ko, T.C., “Optimisation of the EDM process based on the orthogonal array with fuzzy logic and gray relational analysis method,” Int J AdvManuf Technology, 9, 271-277. 2002.
[15]	Samuel, M.P. and Philip, P.K., “Powder metallurgy tool electrodes for electrical discharge machining,” Int J Mach Tools Manuf, 37 (11), 1625-1633. Nov, 1997.
[16]	Lin, Y.C., Yan, B.H. and Huang, F.Y., “Surface modification of Al-Zn-Mg aluminum alloy using the combined process of EDM with USM,” J Mater Process Technology, 115(3), 359-366. Sep, 2001.
[17]	Barash, M.M. and Kahlon, C.S., “Experiments with electric spark toughening,” International Journal of Machine Tool Design & Research, 4, 1-8. June, 1964.
[18]	Mohri, N., Saito, N. and Tsunekawa, Y., “Metal surface modification by electrical discharge machining with composite electrode,” Ann CIRP 42, (1), 219-222. 1993
[19]	Ogata, I. and Mukoyama, Y., “Carburizing and decarburizing phenomena in EDM’d surface,”Int J Jap SocPrecisEngg, 27(3), 197-202. 1993.
[20]	Tsunekawa, Y., Okumiya, M., Mohri, N. and Takahashi, I., “Surface modification of aluminum by electrical discharge alloying,” Mater SciEng, 174(2), 193-198. 1994.
[21]	Singh, S., Maheshwari, S. and Pandey, P. C., “Some investigations in to the electrical discharge machining of hardened tool steel using different electrode materials,” J Mater Process Technol, 149, 272-277. June, 2004.
[22]	Ho, K.H. and Newman, S.T., “State of the art electrical discharge machining (EDM),”International Journal of Machine Tools and Manufacture, 43, 1287-1300. Oct, 2003.
[23]	Venkatesh, V. C. and Parasnis, S., “Surface transformation in high speed steel after electro discharge machining,” Proceedings of 5th AIMTDR Conference, IIT Roorkee, India, 639-649. 1972.
[24]	Koshy, G., Philip, P.K. and Geddam. A., “Hardening of surface layers using electric discharge techniques,” Proceedings of 11th AIMTDR Conference, IIT Madras, 315-319. 1983.
[25]	Khuri, A. L. and Cornell, J.A., “Response surfaces: designs and analyses,” Marcel Dekker Inc., New York, 1996
[26]	Montgomery, D. C., Design and Analysis of Experiments, John Wiley and Sons, New York, 2001.
[27]	Derringer, G. and Suich, R., “Simultaneous optimization of several response variables,” J Qual Technology, 12(4), 214-219. 1980.
[28]	Castillo, E. D., Montgomery, D. C., McCarville, D. R., “Modified desirability functions for multiple response optimization,” J QualTechnol, 28(3), 337-345, 1996.
[29]	Baraskar, S.S., Banwait, S.S. and Laroiya, S.C., “Multi-objective optimisation of electrical discharge machining process using Derringer’s desirability,” Int J Materials Engineering Innovation, 2. 203-221, 2011.