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Optimization of WEDM parameters on surface roughness of EN41B steel
Materials Today: Proceedings xxx (xxxx) xxx
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Optimization of WEDM parameters on surface roughness of EN41B steel B.K. Lodhi a,⇑, S. Agarwal b, Salaman Ahamad a a b
MED, IET, Bundelkhand University, Jhansi 284128, India MED, BIET, Jhansi 284128, India
a r t i c l e
i n f o
Article history: Received 27 March 2019 Received in revised form 16 August 2019 Accepted 23 September 2019 Available online xxxx Keywords: Ra ANOVA WEDM Optimization S/N ratio
a b s t r a c t Now days, CNC WEDM are widely used in industry of mould making, electric components, precision, machinery and components of automobile, army industry. Taguchi method is used to optimization of machining parameters for desired machining response surface roughness in WEDM. The present work is optimizing the cutting parameters in WEDM which are TON, TOFF, IP and WF. Moreover, the important parameters values where find by S/N ratio for the effective performance of Ra. Pulse duration and peak current is the influence factors on Ra. Surface roughness increase with TON and IP. ANOVA were found the most significant parameters of Ra. Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
1. Introduction CNC wire cutting EDM is suitable for machining moulds of conductive materials with high accuracy requirement, high tenacity and hardness and components with complicated shapes. The wire cutting EDM process has salient features of rigidity, long term stability and accuracy keeping, the function and powerful convenient operations. CNC Wire cutting EDM utilizes electrode wire and high frequency power, with control of CNC system, to machine workpiece with spark erosion according to programme track [1]. C. L. Lin et al has investigated optimization of the cutting factors like pulse duration, voltage, wire feed, offset by considering the machining response EWR, MRR, accuracy and surface roughness effectively [2]. Tosun nihat has investigated variation of cutting performance with pulse time, WF and fluid pressure on AISI 4140 steel used as work-piece and Brass wire as tool material [3]. C.B Reddy et al have conducted experiments based on L16 array selecting the P20 Die tool steel as work-piece with molybdenum wire as Tool [4]. Regression analysis was carried out to predict machining characteristics such as MRR and Ra. MRR and SR in WEDM of Nimonic-80A alloy and related to machine surface topography has investigated by Goswami and Kumar [5]. Joshi et al have worked on characteristics of WEDM on Si wafers. Si wafers slicing by CNC wire cut EDM for the application of solar cell [6]. Mussada et al explained the effects of servo feed and wire speed parameters are more responsible for surface hardenability of Die steel [7]. ⇑ Corresponding author. E-mail address: [email protected] (B.K. Lodhi).
Huang et al investigated the effects of cutting parameters such as flushing rate, Ton, wire tension and Toff on cutting groove width and cutting speed, by considering polycrystalline silicon [8]. Puri and Deshpende have reported the study optimizing of parameters by the ANN. Investigate experimentally variation of parameters pulse position, flushing pressure, supply voltage and Toff on MRR and SR [9]. Y Okamoto et al. Brass coated steel wire and silicon carbide was used as electrode and work material respectively. In this study was found that the effect of wire tension on slicing of SiCwith track shaped section [10]. F L Amonim et al. investigation reported that that the comparative study of zinc coated Cu wire and uncoated brass wire. Experimentally found that the Zn coated Cu wire is better performance of kerf width on IN718 alloy as compared to uncoated brass wire [11]. Kumar and Agarwal have investigation found the optimal parameters by the genetic algorithm and Pareto optimizing solution technique [12]. Surface roughness is the important machining responses that play critical role in improve the quality of the engineering parts. Though many researchers have conducted experiments various materials still there is a lacuna in finding correct parameter setting to machine EN41B steel for better quality with reduced cost. But the present experimental study can be achieved, by optimizing the cutting parameters in WEDM process on surface roughness.
2. Experimentation The EX 7732 CNC Wire Electric discharge machine is consists of a reusable molybdenum wire (0.18 mm diameter) as machine tool
https://doi.org/10.1016/j.matpr.2019.09.067 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
2
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx
used in the experimentation. Experimental set up of EX 7732 CNC wire electric discharge machine shown in Fig. 1. Photographic view of machine zone in work-piece shown in Fig. 2. In this study, EN41B steel having composition C-0.037%, Si-0.205%, Cr-1.59%, Mn-0.568%, V-0.006%, Ni-0.026%, Mo-0.248% and Cu-0.037% used as work material for experimentation. During the experiments 5 mm 5 mm square specimen cut to obtain a rectangular punch shown in Fig. 4. JR3A Ointment Gel coolant used in EDM wire cut machine, grinding machine, textile machinery and CNC machines. The different setting of cutting parameters is based on preliminary test on Wire EDM with EN41 B steel taken as work-piece. Different settings of four controlled factor namely pulse duration, pulse off time, wire feed and peak current in Table 1. Mitutoyo surftest SJ210P shown in Fig. 3 is used for surface roughness measurements. 3. Design of experiments Fig. 2. EX7732 WEDM machining zone.
Two concepts coupled in Taguchi method are (i) signal to noise ratio to find the product quality and (ii) L9 array to accommodate different parameters affecting simultaneously examine the performance characteristics [13]. From the Taguchi Technique, an L9 array table was selected Table 2. In this experimental study, main effect plots analysis found by Minitab software. Surface roughness is lower-the-better type characteristics can be calculated by given equating:
g ¼ 10 LOG
n 1X Y2 n i¼1 SR
ð1Þ
4. Results and discussion From the Table 3 the priority level of significant factors characteristics surface roughness are as follows: TON (Rank 1), IP (Rank 2), WF (Rank 3), and TOFF (Rank 4). According to the effect of cutting
parameters in surface roughness shown in Fig. 5 investigate the TON1, TOFF3, IP1 and WF3 for minimization of the surface roughness value of the work-piece. From Fig. 5 the SR was mainly affected by pulse duration, pulse off, peak current and wire feed. From Fig. 5 the Surface roughness increase from 0.5820 to 0.8543 mm as TON was increased by 25–75 ms. As from IP, increasing value of Ra occurred when IP was raise from 1 to 5 A with 0.6543– 0.8467 mm. When the TOFF increase from 5 to 15 ms and WF decrease from 3 to 1 mm/min, show the effect on Ra i.e. 0.7117– 0.772 mm and 0.680–0.810 mm. The SR increase with increase in the pulse duration and current. The higher is the pulse duration and peak current settings, the higher is the discharge energy. There is found to increase the surface roughness. In order to found the good surface roughness during wire EDM of EN41B steel, the optimal combination of
Fig. 1. EX7732 CNC Wire Electric Discharge Machine.
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
3
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx Table 1 Settings of levels for control factors. Parameters Pulse duration Pulse off time Wire feed Peak current
Symbol
Units
Level 1
Levels Level 2
Level 3
TON TOFF WF IP
ms ms mm/min amp
25 05 1 1
50 10 2 3
75 15 3 5
Analysis of variance (ANOVA) is another optimizing tool mentioned in the Taguchi method to further optimize above experimentally results effectively. For the surface roughness the computed F-ratio are shown in Table 4. The F-ratio computed value is F0.05, 1, 2 = 3.5. The concept of F-ratio the most influence parameter TON, IP, WF and remaining factors are estimates error of variance. 4.1. Confirmation experiments The next major step the details of preparation and technique used in confirmation experiments is found the determination of optimal combination of factors TON1, TOFF1, IP1 and WF3. The combination of factors levels TON1, TOFF1, IP1 and WF3 is used to find the SR value by the prediction Eq. (2) Fig. 3. Mitutoyo Surftest SJ210P.
gopt ¼ gm þ
k X
gj gm
ð2Þ
j¼1
machining parameters obtained TON = 25 ms, TOFF = 05 ms, WF = 3 mm/min and IP = 1 A. The % of contribution Ton: 59.11%, IP: 26.18%, WF: 11.928% and error 2.776% shown in Fig. 6.
A new combination of factor level TON1, TOFF1, IP1 and WF3 is used to find the prediction surface roughness gopt = 6.901 db. Experiments conducted by the optimal combination of different
Fig. 4. Specimens of the Work-piece (Rectangular Punch).
Table 2 Experimental results. Parameters
1 2 3 4 5 6 7 8 9
Factor Assignment TON
TOFF
WF
IP
1 1 1 2 2 2 3 3 3
1 2 3 1 2 3 1 2 3
1 2 3 2 3 1 3 1 2
1 2 3 3 1 2 2 3 1
Ra (mm)
S/N Ratio (db)
0.518 0.587 0.641 0.872 0.654 0.885 0.745 1.027 0.791
5.7134 4.6272 3.8628 1.1896 3.6884 1.0611 2.5568 0.2314 2.0364
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
4
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Table 3 Max – Min table for SR. Factors/Levels
L1
L2
L3
Max-Min
Rank
TON TOFF WF IP
0.5820 0.7117 0.8100 0.6543
0.8037 0.7560 0.7500 0.7390
0.8543 0.772 0.6800 0.8467
0.2723 0.0603 0.1300 0.1923‘
1 4 3 2
Fig. 5. Effect of control factors on SR.
Table 5 Confirmation experiments results for SR. Optimal machining parameters
Level S/N ratio for SR (db)
Prediction
Experiments
TON1, TOFF1, IP1, WF3 6.90175
TON1, TOFF1, IP1, WF3 7.145
parameters for performance characteristics Ra as shown in Table 5. From the above observation it can be interrupted that the obtain surface roughness have reasonable results because an error of 3.4% for S/N data of surface roughness 5. Conclusion
Fig. 6. % of parameters in WEDM process.
Optimum condition is being found by the WEDM parameters to get the minimum surface roughness. It is also found that, there is a
Table 4 Pooled ANOVA for SR. Factors
DOF
SS
Variance
F-ratio
Percentage
TON TOFF WF IP Error Total
2 (2) 2 2 2 8
0.125869 Pooled 0.025400 0.055753 0.005913 0.212934
0.62934 – 0.012700 0.027876 0.002956
21.29 – 4.296 9.430 –
59.11 – 11.928 26.18 2.776 100%
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx
improvement in the surface roughness values from the confirmation results. Based on the experimental studies conducted following conclusion can be drawn: During machining is found that increase in pulse duration and IP will results get increase the surface roughness. The optimal machining in WEDM is achieved by the different combination of different levels TON1, TOFF1, IP1 and WF3. Max-min (S/N) concepts found the TON, IP is the most effective parameter of SR. ANOVA found that the TON, IP is the highly % of contribution of the experiments.
References [1] K.H. Ho, S.T. Newman, S. Rahimifard, R.D. Allen, State of the art in wire electrical discharge machining (WEDM), Int. J. Mach. Tools Manuf. 44 (12–13) (2004) 1247–1259. [2] J.L. Lin, C.L. Lin, The use of orthogonal array with grey relational analysis to optimize the electric discharge machining processes with multiple performance characteristics, Int. J. Mach. Tools Manuf. 42 (2002) 237–244. [3] Nihat Tosun, The effect of the cutting parameters on performance of WEDM, KSME Int. J. 17 (6) (2003) 816–824. [4] S. Sivakiran, C.B. Reddy, C.E. Reddy, Effect of process parameters on material removal rate in wire electrical discharge machining of EN-31 steel,
[5]
[6] [7]
[8]
[9]
[10]
[11]
[12]
[13]
5
International journal of Engineering Research and application 79 (3) (2012) 2371–2377. Amitesh Goswami, Jatinder Kumar, Optimization in wire-cut EDM of Nimonic-80A using Taguchi’s approach and utility concept, Eng. Sci. Technol. Int. J. 17 (4) (2014) 236–246. K. Joshi, A. Ananya, U. Bhandarkar, S.S. Joshi, Ulta thin silicon wafers slicing using Wire-EDM for solar cell application, Mater. Des. 124 (2017) 158–170. E.K. Mussada, C.C. Hua, A.K.P. Rao, Surface hardenability studies of the die steel machined by WEDM, Mater. Manuf. Process (2018) 1–6, https://doi.org/ 10.1080/10426914.2018.1476695. Yu. Po-Huai, Hsiang-Kuo Lee, Yang-Xin Lin, Shi-Jie Qin, Biing-Hwa Yan, FuangYuan Huang, Machining characteristics of polycrystalline silicon by wire electrical discharge machining, Mater. Manuf. Processes 26 (12) (2011) 1443– 1450, https://doi.org/10.1080/10426914.2010.544808. Y. M. Puri, N. V. Deshpende, Parametric optimization of WEDM of high chromium high carbon die steel using ANN, ASME International Mechanical Engineering Congress and Exposition, November 5-10, 2006, Chicago, Illinois, USA. A. Kimura, Y. Okamoto, A. Okada, J. Ohya, T. Yamauchi, Fundamental study on multi-wire EDM slicing of SiC by wire electrode with track-shaped section, Proc. CIRP 6 (2013) 232–237. L.W. Reolon, C.A. Henning Laurindo, R.D. Torres, F.L. Amorim, WEDM performance and surface integrity of Inconel alloy IN718 with coated and uncoated wires, Int. J. Adv. Manuf. Technol. (2018), https://doi.org/10.1007/ s00170-018 2828-6. K. Kumar, S. Agarwal, Multi-objective parametric optimization on machining with wire electric discharge machining, Int. J Adv Manuf. Technol. 62 (2012) 617–633. P.J. Ross, Taguchi Techniques for Quality Engineering, Tata McGraw-Hill, New York, 1996.
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Optimization of WEDM parameters on surface roughness of EN41B steel B.K. Lodhi a,⇑, S. Agarwal b, Salaman Ahamad a a b
MED, IET, Bundelkhand University, Jhansi 284128, India MED, BIET, Jhansi 284128, India
a r t i c l e
i n f o
Article history: Received 27 March 2019 Received in revised form 16 August 2019 Accepted 23 September 2019 Available online xxxx Keywords: Ra ANOVA WEDM Optimization S/N ratio
a b s t r a c t Now days, CNC WEDM are widely used in industry of mould making, electric components, precision, machinery and components of automobile, army industry. Taguchi method is used to optimization of machining parameters for desired machining response surface roughness in WEDM. The present work is optimizing the cutting parameters in WEDM which are TON, TOFF, IP and WF. Moreover, the important parameters values where find by S/N ratio for the effective performance of Ra. Pulse duration and peak current is the influence factors on Ra. Surface roughness increase with TON and IP. ANOVA were found the most significant parameters of Ra. Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
1. Introduction CNC wire cutting EDM is suitable for machining moulds of conductive materials with high accuracy requirement, high tenacity and hardness and components with complicated shapes. The wire cutting EDM process has salient features of rigidity, long term stability and accuracy keeping, the function and powerful convenient operations. CNC Wire cutting EDM utilizes electrode wire and high frequency power, with control of CNC system, to machine workpiece with spark erosion according to programme track [1]. C. L. Lin et al has investigated optimization of the cutting factors like pulse duration, voltage, wire feed, offset by considering the machining response EWR, MRR, accuracy and surface roughness effectively [2]. Tosun nihat has investigated variation of cutting performance with pulse time, WF and fluid pressure on AISI 4140 steel used as work-piece and Brass wire as tool material [3]. C.B Reddy et al have conducted experiments based on L16 array selecting the P20 Die tool steel as work-piece with molybdenum wire as Tool [4]. Regression analysis was carried out to predict machining characteristics such as MRR and Ra. MRR and SR in WEDM of Nimonic-80A alloy and related to machine surface topography has investigated by Goswami and Kumar [5]. Joshi et al have worked on characteristics of WEDM on Si wafers. Si wafers slicing by CNC wire cut EDM for the application of solar cell [6]. Mussada et al explained the effects of servo feed and wire speed parameters are more responsible for surface hardenability of Die steel [7]. ⇑ Corresponding author. E-mail address: [email protected] (B.K. Lodhi).
Huang et al investigated the effects of cutting parameters such as flushing rate, Ton, wire tension and Toff on cutting groove width and cutting speed, by considering polycrystalline silicon [8]. Puri and Deshpende have reported the study optimizing of parameters by the ANN. Investigate experimentally variation of parameters pulse position, flushing pressure, supply voltage and Toff on MRR and SR [9]. Y Okamoto et al. Brass coated steel wire and silicon carbide was used as electrode and work material respectively. In this study was found that the effect of wire tension on slicing of SiCwith track shaped section [10]. F L Amonim et al. investigation reported that that the comparative study of zinc coated Cu wire and uncoated brass wire. Experimentally found that the Zn coated Cu wire is better performance of kerf width on IN718 alloy as compared to uncoated brass wire [11]. Kumar and Agarwal have investigation found the optimal parameters by the genetic algorithm and Pareto optimizing solution technique [12]. Surface roughness is the important machining responses that play critical role in improve the quality of the engineering parts. Though many researchers have conducted experiments various materials still there is a lacuna in finding correct parameter setting to machine EN41B steel for better quality with reduced cost. But the present experimental study can be achieved, by optimizing the cutting parameters in WEDM process on surface roughness.
2. Experimentation The EX 7732 CNC Wire Electric discharge machine is consists of a reusable molybdenum wire (0.18 mm diameter) as machine tool
https://doi.org/10.1016/j.matpr.2019.09.067 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Peer-review under responsibility of the scientific committee of the 2nd International Conference on Computational and Experimental Methods in Mechanical Engineering.
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
2
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx
used in the experimentation. Experimental set up of EX 7732 CNC wire electric discharge machine shown in Fig. 1. Photographic view of machine zone in work-piece shown in Fig. 2. In this study, EN41B steel having composition C-0.037%, Si-0.205%, Cr-1.59%, Mn-0.568%, V-0.006%, Ni-0.026%, Mo-0.248% and Cu-0.037% used as work material for experimentation. During the experiments 5 mm 5 mm square specimen cut to obtain a rectangular punch shown in Fig. 4. JR3A Ointment Gel coolant used in EDM wire cut machine, grinding machine, textile machinery and CNC machines. The different setting of cutting parameters is based on preliminary test on Wire EDM with EN41 B steel taken as work-piece. Different settings of four controlled factor namely pulse duration, pulse off time, wire feed and peak current in Table 1. Mitutoyo surftest SJ210P shown in Fig. 3 is used for surface roughness measurements. 3. Design of experiments Fig. 2. EX7732 WEDM machining zone.
Two concepts coupled in Taguchi method are (i) signal to noise ratio to find the product quality and (ii) L9 array to accommodate different parameters affecting simultaneously examine the performance characteristics [13]. From the Taguchi Technique, an L9 array table was selected Table 2. In this experimental study, main effect plots analysis found by Minitab software. Surface roughness is lower-the-better type characteristics can be calculated by given equating:
g ¼ 10 LOG
n 1X Y2 n i¼1 SR
ð1Þ
4. Results and discussion From the Table 3 the priority level of significant factors characteristics surface roughness are as follows: TON (Rank 1), IP (Rank 2), WF (Rank 3), and TOFF (Rank 4). According to the effect of cutting
parameters in surface roughness shown in Fig. 5 investigate the TON1, TOFF3, IP1 and WF3 for minimization of the surface roughness value of the work-piece. From Fig. 5 the SR was mainly affected by pulse duration, pulse off, peak current and wire feed. From Fig. 5 the Surface roughness increase from 0.5820 to 0.8543 mm as TON was increased by 25–75 ms. As from IP, increasing value of Ra occurred when IP was raise from 1 to 5 A with 0.6543– 0.8467 mm. When the TOFF increase from 5 to 15 ms and WF decrease from 3 to 1 mm/min, show the effect on Ra i.e. 0.7117– 0.772 mm and 0.680–0.810 mm. The SR increase with increase in the pulse duration and current. The higher is the pulse duration and peak current settings, the higher is the discharge energy. There is found to increase the surface roughness. In order to found the good surface roughness during wire EDM of EN41B steel, the optimal combination of
Fig. 1. EX7732 CNC Wire Electric Discharge Machine.
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
3
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx Table 1 Settings of levels for control factors. Parameters Pulse duration Pulse off time Wire feed Peak current
Symbol
Units
Level 1
Levels Level 2
Level 3
TON TOFF WF IP
ms ms mm/min amp
25 05 1 1
50 10 2 3
75 15 3 5
Analysis of variance (ANOVA) is another optimizing tool mentioned in the Taguchi method to further optimize above experimentally results effectively. For the surface roughness the computed F-ratio are shown in Table 4. The F-ratio computed value is F0.05, 1, 2 = 3.5. The concept of F-ratio the most influence parameter TON, IP, WF and remaining factors are estimates error of variance. 4.1. Confirmation experiments The next major step the details of preparation and technique used in confirmation experiments is found the determination of optimal combination of factors TON1, TOFF1, IP1 and WF3. The combination of factors levels TON1, TOFF1, IP1 and WF3 is used to find the SR value by the prediction Eq. (2) Fig. 3. Mitutoyo Surftest SJ210P.
gopt ¼ gm þ
k X
gj gm
ð2Þ
j¼1
machining parameters obtained TON = 25 ms, TOFF = 05 ms, WF = 3 mm/min and IP = 1 A. The % of contribution Ton: 59.11%, IP: 26.18%, WF: 11.928% and error 2.776% shown in Fig. 6.
A new combination of factor level TON1, TOFF1, IP1 and WF3 is used to find the prediction surface roughness gopt = 6.901 db. Experiments conducted by the optimal combination of different
Fig. 4. Specimens of the Work-piece (Rectangular Punch).
Table 2 Experimental results. Parameters
1 2 3 4 5 6 7 8 9
Factor Assignment TON
TOFF
WF
IP
1 1 1 2 2 2 3 3 3
1 2 3 1 2 3 1 2 3
1 2 3 2 3 1 3 1 2
1 2 3 3 1 2 2 3 1
Ra (mm)
S/N Ratio (db)
0.518 0.587 0.641 0.872 0.654 0.885 0.745 1.027 0.791
5.7134 4.6272 3.8628 1.1896 3.6884 1.0611 2.5568 0.2314 2.0364
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
4
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx
Table 3 Max – Min table for SR. Factors/Levels
L1
L2
L3
Max-Min
Rank
TON TOFF WF IP
0.5820 0.7117 0.8100 0.6543
0.8037 0.7560 0.7500 0.7390
0.8543 0.772 0.6800 0.8467
0.2723 0.0603 0.1300 0.1923‘
1 4 3 2
Fig. 5. Effect of control factors on SR.
Table 5 Confirmation experiments results for SR. Optimal machining parameters
Level S/N ratio for SR (db)
Prediction
Experiments
TON1, TOFF1, IP1, WF3 6.90175
TON1, TOFF1, IP1, WF3 7.145
parameters for performance characteristics Ra as shown in Table 5. From the above observation it can be interrupted that the obtain surface roughness have reasonable results because an error of 3.4% for S/N data of surface roughness 5. Conclusion
Fig. 6. % of parameters in WEDM process.
Optimum condition is being found by the WEDM parameters to get the minimum surface roughness. It is also found that, there is a
Table 4 Pooled ANOVA for SR. Factors
DOF
SS
Variance
F-ratio
Percentage
TON TOFF WF IP Error Total
2 (2) 2 2 2 8
0.125869 Pooled 0.025400 0.055753 0.005913 0.212934
0.62934 – 0.012700 0.027876 0.002956
21.29 – 4.296 9.430 –
59.11 – 11.928 26.18 2.776 100%
Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067
B.K. Lodhi et al. / Materials Today: Proceedings xxx (xxxx) xxx
improvement in the surface roughness values from the confirmation results. Based on the experimental studies conducted following conclusion can be drawn: During machining is found that increase in pulse duration and IP will results get increase the surface roughness. The optimal machining in WEDM is achieved by the different combination of different levels TON1, TOFF1, IP1 and WF3. Max-min (S/N) concepts found the TON, IP is the most effective parameter of SR. ANOVA found that the TON, IP is the highly % of contribution of the experiments.
References [1] K.H. Ho, S.T. Newman, S. Rahimifard, R.D. Allen, State of the art in wire electrical discharge machining (WEDM), Int. J. Mach. Tools Manuf. 44 (12–13) (2004) 1247–1259. [2] J.L. Lin, C.L. Lin, The use of orthogonal array with grey relational analysis to optimize the electric discharge machining processes with multiple performance characteristics, Int. J. Mach. Tools Manuf. 42 (2002) 237–244. [3] Nihat Tosun, The effect of the cutting parameters on performance of WEDM, KSME Int. J. 17 (6) (2003) 816–824. [4] S. Sivakiran, C.B. Reddy, C.E. Reddy, Effect of process parameters on material removal rate in wire electrical discharge machining of EN-31 steel,
[5]
[6] [7]
[8]
[9]
[10]
[11]
[12]
[13]
5
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Please cite this article as: B. K. Lodhi, S. Agarwal and S. Ahamad, Optimization of WEDM parameters on surface roughness of EN41B steel, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.067