Multi-objective optimization of roundness, cylindricity and areal surface roughness of Inconel 825 using TLBO method in wire electrical discharge turning (WEDT) process

George, Jees; Manu, R.; Mathew, Jose

doi:10.1007/s40430-019-1880-y

Cited by 24 publications

(12 citation statements)

References 40 publications

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“…During the optimization, the surface roughness, flank wear and amplitude of cutter vibration are taken as constraints and they are expected to be less than 2 µm (ISO 1302), 30 µm (ISO 3685:1993) and 30 µm (ISO 10816), respectively, as shown in Eqs. ( 17)- (19).…”

Section: Optimizationmentioning

confidence: 99%

“…Individual and overall constraints for the surface roughness, flank wear and amplitude of cutter vibration are calculated using Eqs. ( 24)-( 27) and ranks are given to the experiments based on the overall constraint values [19,20].…”

Section: Optimizationmentioning

confidence: 99%

“…However, these techniques failed in some applications to handle the optimization due to complexity and ambiguity of objectives in optimization [18]. To overcome these difficulties, new techniques like teaching-learning-based optimization (TLBO) [19] and Taguchi method based graph theory and matrix approach along with utility concept [18] are applied. The Fig.…”

Section: Introductionmentioning

confidence: 99%

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Modeling and optimization of dead metal zone to reduce cutting forces in micro-milling of hardened AISI D2 steel

Babu

Rao

Ben

2021

J Braz. Soc. Mech. Sci. Eng.

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Improving machining performance with reduced power consumption is a big challenge for the manufacturer to reduce production cost. Since the dead metal zone (DMZ) directly affects the cutting forces, the present study aims to optimize the DMZ to reduce the cutting and thrust forces in the micro-milling of hardened AISI D2 steel using teaching-learning-based optimization technique (TLBO). Finite element model for DMZ geometry and mechanistic models for cutting and thrust forces are developed, integrated and estimated the cutting and thrust forces. The estimated forces are compared with experimental results and a good agreement found between them. In the next stage, process parameters (cutting speed and feed per tooth) and tool parameters (nose radius and rake angle) are optimized using TLBO technique to minimize DMZ geometry keeping the surface roughness (≤ 2 µm), tool wear (≤ 30 µm) and amplitude of cutter vibration (≤ 30 µm) as constraints. The optimal working condition is as follows: a spindle speed of 2225 rpm, a feed per tooth of 5.0 µm, and a nose radius of 7.6 µm and rake angle of 3.0°. Under the optimal working condition, side length of DMZ and DMZ angle is found as 13.8 mm and 5.74°, respectively, and the cutting and thrust forces are estimated as 3.27 and 2.37 N, respectively. These cutting and thrust forces are about 21.3-65.7 and 34.8-55.3%, respectively, less than the experimental results.

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Section: Optimizationmentioning

confidence: 99%

Section: Optimizationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Modeling and optimization of dead metal zone to reduce cutting forces in micro-milling of hardened AISI D2 steel

Babu

Rao

Ben

2021

J Braz. Soc. Mech. Sci. Eng.

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“…On comparison, diffusion annealed zinc-coated brass wires outperformed uncoated brass wires with 18.95% and 44.37% for surface roughness and material removal rate criteria, respectively. Jees George [19] used the TLBO (Teaching learningbased optimization) method to optimize the roundness, cylindricity and surface roughness of Inconel 825 in multi-objective optimization in the WEDT process. In addition, the author [20] proposes a calculation technique that uses the time integration effect to simulate the crater formed in the Inconel 825 WEDT process.…”

Section: Introductionmentioning

confidence: 99%

An Investigation on Machining General Size Cylindrical Parts Using WEDM with Contour Approximation Method

Ma¹,

Wang²,

Liu³

et al. 2021

Preprint

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The application of wire EDM to the machining of cylindrical parts is an emerging research topic. The current research is mainly focused on the machining of micro-cylindrical parts, and there is little research on the general-sized parts. This paper proposes to apply the principle of contour approximation method to the machining of cylindrical parts of general size. First, the basic principle of the contour approximation method is introduced, and the machining process is divided into three parts: roughing, semi-finishing and finishing. Roughing corresponds to polygon cutting. Second, the various indicators of polygon cutting are analyzed. The influence of the number of polygonal sides on the residual height and residual area is analyzed. Two methods are proposed for polygon cutting: sequential cutting and multiple edge cutting. The calculation formulas for the processing volume of the two methods are deduced. By comparing the two methods, it is found that different methods are applicable to different part sizes. At last, machining experiments were carried out. The selection of residual variables and the determination of polygon machining methods are detailed. The process parameters and machining time of each stage are listed. In addition, the measurement results of each stage of the machining are also analyzed.

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“…Zaimovic-Uzunovic and Lemes compared the influence of different extraction methods on the cylindricity error through experiments and suggested that different extraction methods had different sensitivities to the probe used in the measurements. 9 Souza et al studied the fitting model and evaluation system of the roundness and cylindricity [10][11][12][13] and concluded that although the roundness and cylindricity were evaluated using similar methods, they had different mathematical models and evaluation systems due to their different properties and working principles. Collins et al 14 discussed the advantages and disadvantages of three measurement schemes-the helicoid line method, Hamspi method, and pie chart method-when measuring the form error with coordinate measuring machines (CMMs).…”

Section: Introductionmentioning

confidence: 99%

A new method for cylindricity error evaluation based on increment-simplex algorithm

Zheng

et al. 2020

Science Progress

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A geometric error determines the quality and function of a product to a certain extent. Cylindricity error is an important indicator of the geometric error of form parts. In recent years, with the development of geometric product verification and specification (GPS), the specification of the cylindricity error and high-precision detection have become the focus in the field of industrial metrology. In this paper, by analyzing the existing cylindricity evaluation strategy, a new method for cylindricity error evaluation based on increment-simplex algorithm is proposed. The purpose is to improve the efficiency of cylindricity error analysis on the basis of ensuring the accuracy requirements. First, according to the GPS specification, the characteristics and applications of the circular section method, the helicoid line method, the generatrix line method, and the bird-cage method for the extraction operation are analyzed. And for the fitting operation, the mathematical models of the cylindricity fitting for the least squares cylinder, minimum circumscribed cylinder, maximum inscribed cylinder, and minimum zone cylinder in cartesian and cylindrical coordinate systems are constructed. Second, a new method of cylindricity error optimization evaluation based on the incremental optimization method is proposed. A theoretical analysis of the new method is made with the circular section method as an example, and the specific steps of cylindricity error analysis based on the circular section method of the new method are given. Finally, experiments and analysis are carried out, and the accuracies and evaluation efficiencies of the cylindricity error of the different cylindricity measurement and evaluation strategies are compared and analyzed. The results and operating efficiency of the increment-simplex algorithm and the traditional algorithms are compared, and the effectiveness and feasibility of the new method are proved.

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Multi-objective optimization of roundness, cylindricity and areal surface roughness of Inconel 825 using TLBO method in wire electrical discharge turning (WEDT) process

Cited by 24 publications

References 40 publications

Modeling and optimization of dead metal zone to reduce cutting forces in micro-milling of hardened AISI D2 steel

Modeling and optimization of dead metal zone to reduce cutting forces in micro-milling of hardened AISI D2 steel

An Investigation on Machining General Size Cylindrical Parts Using WEDM with Contour Approximation Method

A new method for cylindricity error evaluation based on increment-simplex algorithm

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