A particle swarm approach for multi-objective optimization of electrical discharge machining process

Mohanty, Chinmaya P.; Mahapatra, Siba Sankar; Singh, Manas Ranjan

doi:10.1007/s10845-014-0942-3

Cited by 86 publications

(46 citation statements)

References 51 publications

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“…Analysis of the experimental results of surface roughness through Taguchi's OA experimental design are carried (Montgomery 2004;Mohanty et al 2016a). The last column of the table presents the percent contribution of each source of the total variation and indicating the degree of influence on the surface roughness (Mohanty et al 2016b).…”

Section: Surface Roughness Analysismentioning

confidence: 99%

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

Das

Panda

Dhupal

2017

Mech Adv Mater Mod Process

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Background: Now-a-days, newer hardened steel materials are coming rapidly into the market due to its wide applications in various fields of engineering. So the machinability investigation of these steel materials is one of the prime concern for practicing engineers, prior to actual machining. Methods: The present study addresses surface roughness, flank wear and chip morphology during dry hard turning of AISI 4340 steel (49 HRC) using CVD (TiN/TiCN/Al 2 O 3 /TiN) multilayer coated carbide tool. Three factors (cutting speed, feed and depth of cut) and three-level factorial experiment designs with Taguchi's L 9 Orthogonal array (OA) and statistical analysis of variance (ANOVA) were performed to investigate the consequent effect of these cutting parameters on the tool and workpiece in terms of flank wear and surface roughness. For better understanding of the cutting process, surface topography of machined workpieces, wear mechanisms of worn coated carbide tool and chip morphology of generated chips were observed by scanning electron microscope (SEM). Consequently, multiple regression analysis was adopted to develop mathematical model for each response, along with various diagnostic tests were performed to check the validity and efficacy of the proposed model. Finally, to justify the economical feasibility of coated carbide tool in hard turning application, a cost analysis was performed based on Gilbert's approach by evaluating the tool life under optimized cutting condition (suggested by response optimization technique).

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Section: Surface Roughness Analysismentioning

confidence: 99%

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

Das

Panda

Dhupal

2017

Mech Adv Mater Mod Process

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“…Generally, PSO algorithm follows these steps: (i) developing the velocity profiles for the cluster of particles from their lowest and highest value of the input factors, (ii) updating velocity of each particle with respect to its position in each iteration, (iii) determining the fitness function value, and (iv) updating the personal best (p best ) and global best (g best ) for the particles. After finding the g best and p best values, the velocity and position profile of the particles are given by the following equations (Mohanty et al 2016):…”

Section: Response Optimization Using Psomentioning

confidence: 99%

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Panda

Das

Dhupal

2017

Process Integr Optim Sustain

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The paper addresses the assessment, modeling, and optimization study of surface roughness in finish dry hard turning (FDHT) of AISI 4340 steel with coated ceramic tool by considering the cutting speed, axial feed, depth of cut, and nose radius as machining parameters. Thirty sets of longitudinal turning trials based on central composite (CCD) design of experiments (DOEs) are performed, and response surface methodology (RSM), particle swarm optimization (PSO), and finally, Gilbert's approach are subsequently applied for mathematical modeling, response optimization, tool life estimation, and economic analysis. Additionally, various diagnostic tests have been executed to check the statistical significance and validity, adequacy, effectiveness, and fitness of data of the proposed model using analysis of variance (ANOVA) and Anderson-Darling normal probability test. Results indicated that nose radius and feed are the most significant controlled as well as dominant factors for hard turning operation if the minimization of the machined surface roughness is considered. The RSM model combined with PSO technique leads to minimum surface roughness value similar to cylindrical grinding of 0.2021 μm, corresponding to optimum process parameters: 220 m/min of cutting speed, 0.05 mm/rev of feed, 0.193 mm of depth of cut, and 1.6 mm of tool nose radius. Finally, under pre-cited optimum machining conditions, tool life was evaluated to perform cost analysis for the economical justification and feasibility of coated ceramic tools in hard turning. The total machining cost per piece is ensued to be lower ($0.34) as a consequence of higher tool life (44 min), reduction in downtime, and enhancement in savings, which finds economical benefits in hard turning. The novelty aspects of the present work are that (i) it demonstrates the replacement of expensive, time-consuming conventional cylindrical grinding process and proposes the alternative of costlier CBN tool by utilizing coated ceramic tool in hard turning processes considering technological, economical, and ecological aspects, which are helpful and efficient from industrial point of view and (ii) it contributes to practical industrial application of finish hard turning for the shaft and die makers to select the optimum cutting conditions in a range of hardness of 45-55 HRC.

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“…Maximum deviation theory, proposed by Wang [23], can address the issue quite effectively. The computational steps of maximum deviation theory are outlined below to compute the weight of each performance characteristic and finally composite score, which is maximized, is calculated for each alternative [24].…”

Section: Maximum Deviation Theorymentioning

confidence: 99%

Optimization of WEDM process parameters using deep cryo-treated Inconel 718 as work material

Nayak

Mahapatra

2016

Engineering Science and Technology, an International Journal

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A B S T R A C TThe present work proposes an experimental investigation and optimization of various process parameters during taper cutting of deep cryo-treated Inconel 718 in wire electrical discharge machining process. Taguchi's design of experiment is used to gather information regarding the process with less number of experimental runs considering six input parameters such as part thickness, taper angle, pulse duration, discharge current, wire speed and wire tension. Since traditional Taguchi method fails to optimize multiple performance characteristics, maximum deviation theory is applied to convert multiple performance characteristics into an equivalent single performance characteristic. Due to the complexity and nonlinearity involved in this process, good functional relationship with reasonable accuracy between performance characteristics and process parameters is difficult to obtain. To address this issue, the present study proposes artificial neural network (ANN) model to determine the relationship between input parameters and performance characteristics. Finally, the process model is optimized to obtain a best parametric combination by a new meta-heuristic approach known as bat algorithm. The results of the proposed algorithm show that the proposed method is an effective tool for simultaneous optimization of performance characteristics during taper cutting in WEDM process.

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A particle swarm approach for multi-objective optimization of electrical discharge machining process

Cited by 86 publications

References 51 publications

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

Surface Roughness Analysis for Economical Feasibility Study of Coated Ceramic Tool in Hard Turning Operation

Optimization of WEDM process parameters using deep cryo-treated Inconel 718 as work material

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