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G. Rajyalakshmi ¹, P. Venkata Ramaiah ²

Affiliations
1 School of Mechanical and Building Sciences, VIT University, Vellore - 632014, Tamil Nadu, IN
2 2Department of Mechanical Engineering, S. V. University, Tirupati - 517502, Andhra Pradesh, IN

Abstract

Process parameters optimization of multiple response characteristics of WEDM on Inconel-825 super alloy using Fuzzy- Grey relational analysis is presented in this paper. Response characteristics such as MRR, surface finish and spark gap are optimized during wire EDM operation. Process parameters including pulse on time, pulse off time, corner servo voltage, flushing pressure, wire feed, wire tension, servo feed and spark gap voltage are investigated using Taguchi mixed L36 orthogonal array. These response characteristics are studied and examined using grey-fuzzy approach and optimal combination of influential input parameters are discovered. Based on the results of verification experiments it is concluded that Taguchi, Fuzzy-Grey Relational Analysis can efficaciously be used to find the optimal combination of influential input parameters of WEDM. Hence, this paper supports that the suggested approach can be a useful tool to ameliorate the performance of WEDM on Inconel-825.

Keywords

Fuzzy-Grey Relational Analysis, Inconel-825, Optimization, Taguchi Method, Wire EDM

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G. Rajyalakshmi ¹, P. Venkata Ramaiah ²

Affiliations
1 School of Mechanical and Building Sciences, Vellore Institute of Technology, Vellore, Tamilnadu, IN
2 Department of Mechanical Engineering, Sri Venkateswara University, Tirupati, Andhra Pradesh, IN

Abstract

In this paper, fuzzy logic integrated with the Taguchi method is used to optimize Wire Electro Discharge Machining (WEDM) process with multiple quality characteristics. Rough machining with EDM gives poor surface finish and has micro cracks and pores. Finish machining gives better surface finish but with very poor machining speed (MRR). Spark gap width is one of the important performance measures in WEDM. Spark gap width is the measure of the amount of the material that is wasted during machining. It determines the dimensional accuracy of the finishing part. In setting the machining parameters, the main goal is the maximum MRR with the minimum surface roughness and minimum spark gap width. Hence achieving higher MRR along with lower SR and SG can be considered as a multi-objective optimization problem. This paper discusses the application of the Taguchi method with fuzzy logic to optimize the machining parameters for Wire electrical discharge machining of Inconel 825 with multiple characteristics. A multi-response performance index (MRPI) was used for optimization. The machining parameters viz., pulse on time, pulse off time, corner servo voltage, flushing pressure, wire feed, wire tension, spark gap voltage, servo feed were optimized with consideration of multiple performance characteristics. The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process.

Keywords

WEDM, Inconel 825, Taguchi Method, Fuzzy Logic, Multi Objective Optimization.

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G. Rajyalakshmi ¹

Affiliations
1 School of Mechanical Engineering, VIT University, Vellore – 632014, Tamil Nadu, IN

Abstract

This research paper focused on development of a multi response optimization technique, using traditional utility – Taguchi method in conjunction with the principal component analysis for weight assignment concept in Wire Electrical Discharge Machining (WEDM). Inconel-825 super alloy has been selected as work material for experimentation. The effect of process parameters such pulse on time (TON), pulse off time (TOFF), Corner Servo voltage (CS), flushing pressure (WP), Wire Feed (WF), Wire Tension (WT), Spark Gap Voltage (SV) and Servo Feed (SV) were investigated on Material Removal Rate (MRR), Surface Roughness (SR) and Spark Gap (SG) in WEDM operation. Further, the responses such as MRR, SR and SG were modelled empirically through regression analysis. The optimization of multiple responses has been done for satisfying the requirements of industrial users, in contrast to the traditional multi-response techniques. Finally, confirmation experiment was performed to validate the effectiveness of the proposed optimal condition.

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