Optimization of Machine Process Parameters in EDM for EN 31 Using Evolutionary Optimization Techniques

Abstract

Electrical discharge machining (EDM) is a non-conventional machining process that is used for machining of hard-to-machine materials, components in which length to diameter ratio is very high or products with a very complicated shape. The process is commonly used in automobile, chemical, aerospace, biomedical, and tool and die industries. It is very important to select optimum values of input process parameters to maximize the machining performance. In this paper, an attempt has been made to carry out multi-objective optimization of the material removal rate (MRR) and roughness parameter (Ra) for the EDM process of EN31 on a CNC EDM machine using copper electrode through evolutionary optimization techniques like particle swarm optimization (PSO) technique and biogeography based optimization (BBO) technique. The input parameter considered for the optimization are Pulse Current (A), Pulse on time (µs), Pulse off time (µs), and Gap Voltage (V). PSO and BBO techniques were used to obtain maximum MRR and minimize the Ra. It was found that MRR and SR increased linearly when discharge current was in mid-range however non-linear increment of MRR and Ra was found when current was too small or too large. Scanning Electron Microscope (SEM) images also indicated a decreased Ra. In addition, obtained optimized values were validated for testing the significance of the PSO and BBO technique and a very small error value of MRR and Ra was found. BBO outperformed PSO in every aspect like computational time, less percentage error, and better optimized values.

Wire Tool Electrode Behavior and Wear under Discharge Pulses

“…Time intermittent pause to ensure the stability of the processing process, Dielectric pressure in nozzles for flushing, F l 245 1 Provided in equivalent unit of the machine.…”

“…The subject of electrical discharge machining (EDM) and wear of a wire tool electrode is not new, but the physical processes that occur during processing are still not sufficiently studied [1][2][3][4]. It is related to the absence of the possibility of visual control over the processes occurring in the discharge gap during EDM especially for large workpieces [5,6].…”

Optimization of Electro-Discharge Texturing Parameters for Steel Sheets’ Finishing Rollers

“…In application of electro-discharge texturing, the material is removed by repeated discharges that cause local melting or evaporation of material from the surface of the heat-treated roller [8]. The resulting texture of working rollers depends on the size of craters, or on the amount of material removed Q vi .…”

Comparison of Micro-EDM Characteristics of Inconel 706 between EDM Oil and an Al Powder-Mixed Dielectric

“…Consequently, EDM (electrical discharge machining) has become an effective way to machine Inconel alloys. With the greatly increased demand for fabricating advanced materials, EDM has been found to be a superior processing method compared with traditional machining [3][4][5]. Additionally, EDM plays an important role in the modern manufacturing industry, especially in the areas of defense, aerospace, and special materials applications, and has been developed as an alternative to machining Inconel alloys [6].…”