Multi-objective optimization of some correlated process parameters in EDM of Inconel 800 using a hybrid approach

Paul, Tania; Saha, Abhijit; Majumder, Himadri; Dey, Vidyut; Dutta, Prasenjit

doi:10.1007/s40430-019-1805-9

Cited by 31 publications

(9 citation statements)

References 32 publications

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“…Relational Coefficient The OQPI ranking selects the optimal solution. [20] PCA-based Utility theory WS Weighted Score, the same as MPI [21][22][23] PCA-Based TOPSIS OPI Overall Performance Index [24,25] PCA-Based MOORA Weights for calculating the Assessment of the overall assessment value based on the PCA eigenvectors' squares. [26] Neuro-fuzzy-PCA-The weights used for training the neuro-fuzzy model are the square of the PCA eigenvectors.…”

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of inconel 718 turning parameters using PCA-MARCOS and MARCOS-Taguchi

et al. 2023

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In recent years, multiple-attribute decision-making (MADM) methods have gathered significant interest from researchers across various scientific fields. In the case of mechanical part machining when faced with conflicting objectives, these methods have become essential in the selection of necessary cutting parameters.. The integration of these techniques with multi-objective optimization procedures has proven effective in leading to an efficient solution to a multi-attribute decision-making problem. The present study falls within this context. Its primary objective being the determination of the optimal cutting parameters that reduces tool vibration, minimizes surface roughness along withmaximizing material removal rate during the turning of Inconel 718 using a coated carbide cutting tool grade (GC1105). These various objectives have been achieved through combining the principal component analysis (PCA) method to the measurement of alternatives and ranking according to the compromise solution (MARCOS), and MARCOS method coupled with the Taguchi SN ratio. The results obtained demonstrated that both methods generated the same combination of optimal cutting parameters that achieve the aforementioned objectives and represented by a nose radius r = 0.8 mm, a cutting speed Vc = 70 mm/min, a feed rate f = 0.08 mm/rev, and a depth of cut ap = 0.3 mm.

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Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of inconel 718 turning parameters using PCA-MARCOS and MARCOS-Taguchi

et al. 2023

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“…However, the location of areas with the highest electrical field strength is also affected by contamination of the dielectric fluid in the IEG by electroconductive particles, which are produced during the EDM process [25][26][27][28]. The distribution of dispersed contaminants over the IEG volume is random and depends on a number of factors including the IEG dimensions [23,29,30], the applied voltage [30,31], the pulse frequency and duty cycle of the discharges [30][31][32][33][34], the workpiece and tool materials [33], the speed, at which the dielectric fluid (typically mineral oil) is pumped [30,35], the thickness of the workpiece being processed and the size of particles being removed from the IEG [35,36]. To ensure the stability of the ED process, it is necessary to maintain the removal of contaminants from the dielectric fluid at a rate that is no less than that at which the new electroerosion products contaminating the IEG are produced [35].…”

Section: Introductionmentioning

confidence: 99%

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

Grigoriev

Pivkin

Kozochkin

et al. 2021

Metals

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The field of applied wire electrical discharge machining (WEDM) is rapidly expanding due to rapidly increasing demand for parts made of hard-to-machine materials. Hard alloys composed of WC, TiC and Co are advanced cutting materials widely used in industry due to the excellent combination of hardness and toughness, providing them obvious advantages over other cutting materials, such as cubic boron nitride, ceramics, diamond or high-speed steel. A rational choice of the WEDM modes is extremely important to ensure the dimensional quality of the manufactured cutting inserts, while roughness of the machined surface on the cutting edge is of great importance with regards to the application of wear-resistant coatings, which increases tool life. However, the stock control systems of CNC WEDM machines, which are based on assessment of electrical parameters such as amperage and voltage, are unable to timely detect conditions at which a threat of wire breakage appears and to prevent wire breakage by stopping the electrode feed and flushing out the interelectrode gap (IEG) when hard alloys with high heat resistance and low heat conductivity, such as WC, TiC and Co composites, are being machined, due to the inability to distinguish the working pulses and pulses that expend a part of their energy heating and removing electroerosion products contaminating the working zone. In this paper, the physicomechanical nature of the WEDM of hard alloy WC 88% + TiC 6% + Co 6% was investigated, and the possibility of using acoustic emission parameters for controlling WEDM stability and productivity were explored. Acoustic emission (AE) signals were recorded in octave bands with central frequencies of 1–3 and 10–20 kHz. It was found that at the initial moment, when the dielectric fluid is virtually free of contaminants, the amplitude of the high-frequency component of the VA signal has its highest value. However, as the contamination of the working zone by electroerosion products increases, the amplitude of the high-frequency component of the AE signal decreases while the low-frequency component increases in an octave of 1–3 kHz. By the time of the wire breakage, the amplitude of the high-frequency component in the octave of 10–20 kHz had reduced by more than 5-fold, the amplitude of the low-frequency component in the octave of 1–3 kHz had increased by more than 2-fold, and their ratio, coefficient Kf, decreased by 12-fold. To evaluate the efficiency of Kf as a diagnostic parameter, the quality of the surface being machined was investigated. The analysis of residual irregularities on the surface at the electrode breakage point showed the presence of deep cracks and craters typical of short-circuit machining. It was also found that the workpiece surface was full of deposits/sticks, whose chemical composition was identical to that of the wire material. The presence of the deposits evidenced heating and melting of the wire due to the increased concentration of contaminants causing short circuits. It was also shown that the wire breakage was accompanied by the “neck” formation, which indicated simultaneous impacts of the local heating of the wire material and tensile forces. Due to the elevated temperature, the mechanical properties the wire material are quickly declining, a “neck” is being formed, and, finally, the wire breaks. At the wire breakage point, sticks/deposits of the workpiece material and electroerosion products were clearly visible, which evidenced a partial loss of the pulses’ energy on heating the electroerosion products and electrodes. A further increase in the contamination level led to short circuits and subsequent breakage of the wire electrode. It was shown that in contrast to the conventional controlling scheme, which is based on the assessment of amperage and voltage only, the analysis of VA signals clearly indicates the risk of wire breakage due to contamination of the working zone, discharge localization and subsequent short circuits. The monotonic dependence of WEDM productivity on AE parameters provides the possibility of adaptive adjustment of the wire electrode feed rate to the highest WEDM productivity at a given contamination level. As the concentration of contaminants increases, the feed rate of the wire electrode should decrease until the critical value of the diagnostic parameter Kf, at which the feed stops and the IEG flushes out, is reached. The link between the AE signals and physicomechanical nature of the WEDM of advanced cutting materials with high heat resistance and low heat conductivity in different cutting modes clearly shows that the monitoring of AE signals can be used as a main or supplementary component of control systems for CNC WEDM machines.

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“…The state of the IEG has concentrated most of the parameters that are difficult or impossible to control in the EDM process, so its assessment is carried out indirectly, for example, by current. However, this does not give a complete picture of what is happening with EDM, and even more so does not allow you to estimate in advance certain EDM parameters necessary for setting up the generator [1].…”

Section: Introductionmentioning

confidence: 99%

Application of Circuit Modeling in the Study of Spark Formation During Electroerosion Treatment

Porvatov¹,

Kozochkin²,

Minin³

et al. 2021

EPJ Web Conf.

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Electrical discharge machining (EDM) of a workpiece is a complex, fast-flowing process characterized by alternating (intermittent) states: short circuit, idle and spark formation. The discontinuity of the EDM process means that the processing is carried out in single pulses, which are formed by a special pulse generator. The parameters of the generator pulses can be divided into time and electrical. The time period and duration of the pulses, as well as the difference between these two parameters (the “silence” interval), are considered temporary. The electric ones include the amplitude value of the voltage, the maximum permissible current, and the polarity of the pulses. in addition, depending on the device of the generator, the pulses can be composite, for example, have an igniting pulse with a higher voltage and a lower current than the main (working) pulse. In this work, we have developed a interelectrode gap model that allows not only to obtain values of electrical parameters, but also to evaluate and to optimize the electrical parameters of materials being processed with known electrical properties. The key advantage of this model is its modularity, which allows to add new functional blocks, which describe external and internal influences, for example, the concentration of erosion products, uneven electrical conductivity of the workpiece, and others, without changing its structure.

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Multi-objective optimization of some correlated process parameters in EDM of Inconel 800 using a hybrid approach

Cited by 31 publications

References 32 publications

Multi-objective optimization of inconel 718 turning parameters using PCA-MARCOS and MARCOS-Taguchi

Multi-objective optimization of inconel 718 turning parameters using PCA-MARCOS and MARCOS-Taguchi

Physicomechanical Nature of Acoustic Emission Preceding Wire Breakage during Wire Electrical Discharge Machining (WEDM) of Advanced Cutting Tool Materials

Application of Circuit Modeling in the Study of Spark Formation During Electroerosion Treatment

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