PurposeThe main objective of this experimental work is to analyze and measure the form tolerances... more PurposeThe main objective of this experimental work is to analyze and measure the form tolerances namely flatness and squareness while machining a meso deep hole in EDM on Inconel-718 material plate.Design/methodology/approachThe experiments were performed on 15 amps rated SPARKONIX-EDM as per DOE (design of experiments). Kerosene was used as a dielectric along with constant pressure of 0.2 kg/cm2 for all trial runs. The currents Ton and Toff were selected as process constraints to conduct experimental trials. The MRR, EWR, machining time and form tolerances were considered as output responses. The experimental outcomes were optimized by hybrid optimization using Taguchi and GRA (grey relational analysis) method.FindingsThe EDM process parameters for Ni-based super alloy namely Inconel-718 had optimized by using GRA method coupled with Taguchi method. The optimum solution has been calculated for MRR, EWR, machining time and form tolerances namely squareness and flatness. The optimiz...
International Journal of Decision Support System Technology
The applications of artificial intelligence (AI) are becoming more popular and relevant research ... more The applications of artificial intelligence (AI) are becoming more popular and relevant research have been conducted in every field of engineering and science by using these AI techniques. Therefore, this research aims to examine the influence of wire electric-discharge machining (WEDM) parameters on performance parameters to improve the productivity with a higher surface finish of titanium alloy (Ti-6Al-4V) by using the artificial intelligent technique. In this experimental analysis, the Adaptive Network Based fuzzy Inference System (ANFIS) model has been highly-developed and the multi-parametric optimization has been done to find the optimal solution for the machining of the titanium superalloy. The peak current (Ip), taper angle, pulse on time (Ton), pulse of time (Toff) and the dielectric fluid flow rate were selected as operation constraints to conduct experimental trials. The surface roughness (SR) and MRR were considered as output responses. The influence on machining perform...
This research aims to examine the machinability and form tolerances in die sinking EDM for Ni-bas... more This research aims to examine the machinability and form tolerances in die sinking EDM for Ni-based superalloy with different diameter internally engraved hole of the multi-hole copper electrode. Manufacturing of superalloys with close tolerances is becoming a major area for primary research in defence and aerospace industries due to their particular characteristics. Therefore, this work focuses on an experimental analysis to improve the productivity and Material Removal Rate of Inconel-718 with close tolerances. The most dominating process constraints, viz. hole diameter of Multi-hole electrode (D), Peak current (I p), Pulse on Time (T on) and dielectric fluid pressure were selected as process constraints to conduct experimental trials. The Material Removal Rate, EWR and form tolerances were considered as output responses. The experimental outcomes were optimized by Taguchi analysis and multi-parametric optimization method GRA. A Fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, EWR, circularity and cylindricity with respect to changes in input parameters. Three MF's ('Trimf-triangular membership functions') were allocated to each input response, whereas five MF's were allocated to output responses. The Fuzzy model shows the 94.01% accuracy between the experimental values and the predicted values. From the results, it is concluded that the use of a multi-hole electrode leads to a higher rate of MRR. Moreover, the form tolerance deviation improves with the increment of T on value. The optimized parameters showed a considerable improvement in the process and will facilitate the aerospace and defence industries to improve the productivity of Inconel-718 with close tolerance.
The applications of artificial intelligence (AI) mainly, the hybrid approaches are becoming more ... more The applications of artificial intelligence (AI) mainly, the hybrid approaches are becoming more popular and the relevant researches have been conducted in every field of engineering and science by using these AI techniques. Therefore, this research aims to examine the influence of wire electric-discharge machining parameters on performance parameters to improve the productivity with a higher surface finish of Titanium alloy (Ti-6Al-4V) by using the artificial intelligent technique. In this experimental analysis, the adaptive network based fuzzy inference system (ANFIS) model has been highly-developed and the multi-parametric optimization has been done to find the optimal solution for the machining of titanium superalloy. The peak current (I p), taper angle, pulse on time (T on), pulse of time (T off) and the dielectric fluid flow rate had selected as operation constraints to conduct experimental trials. The surface roughness and MRR were considered as output responses. The influence on machining performance has been analyzed by the ANFIS model and the developed model was validated with the full factorial regression models. The developed models showed the minimum mean percentage error and the optimized parameters by the GRA method showed the considerable improvement in the process.
5-axis CNC wire EDM is the greatest innovation usually called as the revolutionary machining proc... more 5-axis CNC wire EDM is the greatest innovation usually called as the revolutionary machining process affecting the modern machine tool and precision machining industries. WEDM has acquired improvements to the machining industry in product accuracy, quality and profitability. In the early stages, costly conventional processes were frequently used in the production, however, now with the aid of computer numerical controlled WEDM machines, intricate, complex shape and hard materials (Hardened D2, Tungsten Carbides, high carbon tool steel, composites etc.) can be machined automatically and precisely at low costs. Components having superior properties, higher surface finish, precise and close tolerances are the most important requirements in industries and to achieve these requirements, highly precise, non-conventional machining processes are preferred. This paper presents the review of 5-axis CNC WEDM, its developments, experimental analysis, literature survey for optimization of WEDM process parameters and its effect on the properties and performance parameters of the materials.
PurposeThe main objective of this experimental work is to analyze and measure the form tolerances... more PurposeThe main objective of this experimental work is to analyze and measure the form tolerances namely flatness and squareness while machining a meso deep hole in EDM on Inconel-718 material plate.Design/methodology/approachThe experiments were performed on 15 amps rated SPARKONIX-EDM as per DOE (design of experiments). Kerosene was used as a dielectric along with constant pressure of 0.2 kg/cm2 for all trial runs. The currents Ton and Toff were selected as process constraints to conduct experimental trials. The MRR, EWR, machining time and form tolerances were considered as output responses. The experimental outcomes were optimized by hybrid optimization using Taguchi and GRA (grey relational analysis) method.FindingsThe EDM process parameters for Ni-based super alloy namely Inconel-718 had optimized by using GRA method coupled with Taguchi method. The optimum solution has been calculated for MRR, EWR, machining time and form tolerances namely squareness and flatness. The optimiz...
International Journal of Decision Support System Technology
The applications of artificial intelligence (AI) are becoming more popular and relevant research ... more The applications of artificial intelligence (AI) are becoming more popular and relevant research have been conducted in every field of engineering and science by using these AI techniques. Therefore, this research aims to examine the influence of wire electric-discharge machining (WEDM) parameters on performance parameters to improve the productivity with a higher surface finish of titanium alloy (Ti-6Al-4V) by using the artificial intelligent technique. In this experimental analysis, the Adaptive Network Based fuzzy Inference System (ANFIS) model has been highly-developed and the multi-parametric optimization has been done to find the optimal solution for the machining of the titanium superalloy. The peak current (Ip), taper angle, pulse on time (Ton), pulse of time (Toff) and the dielectric fluid flow rate were selected as operation constraints to conduct experimental trials. The surface roughness (SR) and MRR were considered as output responses. The influence on machining perform...
This research aims to examine the machinability and form tolerances in die sinking EDM for Ni-bas... more This research aims to examine the machinability and form tolerances in die sinking EDM for Ni-based superalloy with different diameter internally engraved hole of the multi-hole copper electrode. Manufacturing of superalloys with close tolerances is becoming a major area for primary research in defence and aerospace industries due to their particular characteristics. Therefore, this work focuses on an experimental analysis to improve the productivity and Material Removal Rate of Inconel-718 with close tolerances. The most dominating process constraints, viz. hole diameter of Multi-hole electrode (D), Peak current (I p), Pulse on Time (T on) and dielectric fluid pressure were selected as process constraints to conduct experimental trials. The Material Removal Rate, EWR and form tolerances were considered as output responses. The experimental outcomes were optimized by Taguchi analysis and multi-parametric optimization method GRA. A Fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, EWR, circularity and cylindricity with respect to changes in input parameters. Three MF's ('Trimf-triangular membership functions') were allocated to each input response, whereas five MF's were allocated to output responses. The Fuzzy model shows the 94.01% accuracy between the experimental values and the predicted values. From the results, it is concluded that the use of a multi-hole electrode leads to a higher rate of MRR. Moreover, the form tolerance deviation improves with the increment of T on value. The optimized parameters showed a considerable improvement in the process and will facilitate the aerospace and defence industries to improve the productivity of Inconel-718 with close tolerance.
The applications of artificial intelligence (AI) mainly, the hybrid approaches are becoming more ... more The applications of artificial intelligence (AI) mainly, the hybrid approaches are becoming more popular and the relevant researches have been conducted in every field of engineering and science by using these AI techniques. Therefore, this research aims to examine the influence of wire electric-discharge machining parameters on performance parameters to improve the productivity with a higher surface finish of Titanium alloy (Ti-6Al-4V) by using the artificial intelligent technique. In this experimental analysis, the adaptive network based fuzzy inference system (ANFIS) model has been highly-developed and the multi-parametric optimization has been done to find the optimal solution for the machining of titanium superalloy. The peak current (I p), taper angle, pulse on time (T on), pulse of time (T off) and the dielectric fluid flow rate had selected as operation constraints to conduct experimental trials. The surface roughness and MRR were considered as output responses. The influence on machining performance has been analyzed by the ANFIS model and the developed model was validated with the full factorial regression models. The developed models showed the minimum mean percentage error and the optimized parameters by the GRA method showed the considerable improvement in the process.
5-axis CNC wire EDM is the greatest innovation usually called as the revolutionary machining proc... more 5-axis CNC wire EDM is the greatest innovation usually called as the revolutionary machining process affecting the modern machine tool and precision machining industries. WEDM has acquired improvements to the machining industry in product accuracy, quality and profitability. In the early stages, costly conventional processes were frequently used in the production, however, now with the aid of computer numerical controlled WEDM machines, intricate, complex shape and hard materials (Hardened D2, Tungsten Carbides, high carbon tool steel, composites etc.) can be machined automatically and precisely at low costs. Components having superior properties, higher surface finish, precise and close tolerances are the most important requirements in industries and to achieve these requirements, highly precise, non-conventional machining processes are preferred. This paper presents the review of 5-axis CNC WEDM, its developments, experimental analysis, literature survey for optimization of WEDM process parameters and its effect on the properties and performance parameters of the materials.
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Papers by S. Dhanabalan