Experimental modeling and multi-objective optimization of traveling wire electrochemical spark machining (TW-ECSM) process

Bhuyan, Basanta Kumar; Yadava, Vinod

doi:10.1007/s12206-013-0632-7

Cited by 37 publications

(8 citation statements)

References 13 publications

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“…This technique enables each factor to be independently evaluated with randomized experiments due to the orthogonal array (OA) consisting of a balanced design with equally weighted factor levels hence eliminating the possibility of one factor effecting the estimation of another factor. The ability to narrow the range of specific study or identifying problems in manufacturing process with existing data by means of emphasizing a mean performance characteristic value close to the target value rather than a value within certain specification limits has made the Taguchi method a popular choice for improving product quality [17,[20][21][22].…”

Section: Taguchi and Multi-objective Taguchi Methodsmentioning

confidence: 99%

“…With the capability of being able to model a relationship between the quantitative factors and the response, this method can often be used to identify new operating settings that produce established improvement in product quality over the quality achieved by existing conditions with negligible errors. However, a true functional relationship between independent variables and the response surface is essential to determine an apposite approximation [20].…”

Section: Response Surface Methodology (Rsm)mentioning

confidence: 99%

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Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology

2015

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This study presents the effect of the governing parameters in friction stir welding (FSW) on the mechanical properties and weld quality of a 6mm thick 6061 T651 Aluminum alloy butt joint. The main FSW parameters, the rotational and traverse speed were optimized based on multiple mechanical properties and quality features, which focus on the tensile strength, hardness and the weld quality class using the multi-objective Taguchi method (MTM). Multi signal to noise ratio (MSNR) was employed to determine the optimum welding parameters for MTM while further analysis concerning the significant level determination was accomplished via the well-established analysis of variance (ANOVA). Furthermore, the first order model for predicting the mechanical properties and weld quality class is derived by applying response surface methodology (RSM). Based on the experimental confirmation test, the proposed method can effectively estimate the mechanical properties and weld quality class which can be used to enhance the welding performance in FSW or other applications.

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Section: Taguchi and Multi-objective Taguchi Methodsmentioning

confidence: 99%

Section: Response Surface Methodology (Rsm)mentioning

confidence: 99%

Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology

2015

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“…In subsequent experimentation, [65][66][67], multi-response optimization of parameters such as surface roughness and MRR in magnetic field-assisted TW-ECSM process was performed and it was found that supplied voltage had the highest effect on both parameters. The next most effective parameters were found to be the wire feed rate and the electrolyte concentration.…”

Section: Electrochemical Machining/ Electrochemical Discharge Machinimentioning

confidence: 99%

A review of magnetic-assisted machining processes

Peruri

Chaganti

2019

J Braz. Soc. Mech. Sci. Eng.

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There has been an increasing interest in the penetration of magnetic field-assisted machining processes in the industries. Due to the ease of contactless forces, magnetic fields have proved extremely versatile and relatively low cost when considering the potential increase in productivity of existing machining processes that it can provide. In this overview, we review the recent achievements and developments in magnetic field-assisted machining processes and their applications. A wide variety of machining domains are examined including electro-discharge machining (EDM), micro-EDM, electrochemical machining, magnetic-assisted machining and many more. The advantages and limitations of each implementation and potential future research pathways are also discussed.

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“…The challenging task in the field of MEMS and microfluidics is to develop fluidic channels and holes in borosilicate glass substrates with fewer defects. Electrochemical discharge machining process has already proved its potential to machine various features on glass and ceramics [1][2][3][4][5]. But the difficulty in achieving dimensional accuracy, surface integrity and process control limits the application of ECDM in modern industries.…”

Section: Introductionmentioning

confidence: 99%

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

Ladeesh

Manu

2018

J Braz. Soc. Mech. Sci. Eng.

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Machining of advanced glass ceramics is of great importance and is a challenging task for the modern industries. In this study, a new hybrid technique of grinding-aided electrochemical discharge drilling (G-ECDD) is attempted which combines the grinding action of a rotating abrasive tool and thermal melting action of electrochemical discharges to perform drilling of borosilicate glass. G-ECDD is performed using a normal electrochemical discharge machine setup with a provision for using a rotating diamond-coated drill tool. The tool used is a hollow diamond core drill rather than the traditional solid abrasive tool. A spring-fed tool system was designed and developed to provide the tool-feed movement which will also help to maintain a balance between grinding action of diamond grits and thermal melting action of discharges. Preliminary experiments are conducted to identify the optimum spring force of the spring-fed system and tool rotational speed which can facilitate a balanced ECDM and grinding action for material removal. The effect of machining parameters like voltage, duty ratio, pulse cycle time and electrolyte concentration on material removal rate (MRR) and hole radial overcut (ROC) is investigated using response surface methodology (RSM). Duty ratio and voltage are found to be the most significant factors contributing MRR. Voltage and pulse cycle time are identified as the main factors controlling radial overcut of the drilled holes. Second-order regression models for MRR and ROC are developed using the data collected from the experiments using RSM. Grey relational analysis was used to optimize this multi-objective problem. A voltage of 90 V, duty ratio of 0.7, cycle time of 0.002 s and an electrolyte concentration of 3.5 M are found to be the best combination for optimizing the responses. Deterioration of bonding material and dislodging of diamond grits are found to be the major modes of tool wear during G-ECDD. The use of high-frequency pulsed DC increased the tool wear rate due to the less time available for heat dissipation between discharge cycles. Moreover, the wear at the end face of the tool will be accelerated due to the concentration of current density at edges during high-frequency operation. From the microscopic images of the machined surface, the material removal mechanisms involved in G-ECDD are found to be a combination of thermal melting by discharges, grinding action of diamond grits and high-temperature chemical etching effect of the electrolyte.

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Experimental modeling and multi-objective optimization of traveling wire electrochemical spark machining (TW-ECSM) process

Cited by 37 publications

References 13 publications

Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology

Model development for mechanical properties and weld quality class of friction stir welding using multi-objective Taguchi method and response surface methodology

A review of magnetic-assisted machining processes

Performance evaluation and multi-response optimization of grinding-aided electrochemical discharge drilling (G-ECDD) of borosilicate glass

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