Performance Measurement and Data Analysis of Material Removal Rate for Wire Cut Electro Discharge Machining Process

Abstract:

In this paper, statistical and regression analysis of material removal rate using design of experiments is proposed for WEDM operations. Experimentation was planned as per Taguchi’s mixed orthogonal array. Each experiment has been performed under different cutting conditions of gap voltage, pulse ON time, pulse OFF time, wire feed and dielectric flushing pressure. Stainless Steel grade 304L was selected as a work material to conduct the experiments. From experimental results, the material removal rate was determined for each machining performance criteria. Analysis of variance (ANOVA) technique was used to find out the variables affecting the material removal rate. Assumptions of ANOVA were discussed and carefully examined using analysis of residuals. Variation of the material removal rate with machining parameters was mathematically modeled by using the regression analysis method. The developed model was validated with a set of experimental data and appeared to be satisfactory. Signal to noise ratio was applied to measure the performance characteristics deviating from the actual value. Finally, experimental confirmation was carried out to identify the effectiveness of this proposed method.

• Periodical: Applied Mechanics and Materials (Volumes 110-116)
• Pages: 1683-1690
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.110-116.1683
• Online since: October 2011
• Authors: Vishal Parashar, A. Rehman, J.L. Bhagoria
• Keywords: ANOVA, MRR, S/N Ratio, Taguchi Method, WEDM

References

[1] K. Kanlayasiri, S. Boonmung, An investigation on effects of wire-EDM machining parameters on surface roughness of newly developed DC53 die steel, journal mater. Process. technol. 187-188, 26-29, (2007).

DOI: 10.1016/j.jmatprotec.2006.11.220

[2] P.M. George, B.K. Raghunath, L.M. Manocha, Ashish M. Warrier, EDM machining of carbon–carbon composite—a Taguchi approach, Journal of Materials Processing Technology, 145, 66–71, (2004).

DOI: 10.1016/s0924-0136(03)00863-x

[3] R. Ramakrishnan, L. Karunamoorthy, Multi response optimization of wire EDM operations using robust design of experiments, Int J Adv Manuf Technol 29, 105–112, (2006).

DOI: 10.1007/s00170-004-2496-6

[4] Shajan Kuriakose, M.S. Shunmugam, Multi-objective optimization of wire-electro discharge machining process by Non-Dominated Sorting Genetic Algorithm, journal mater. Process. technol. 170, 133-14, (2005).

DOI: 10.1016/j.jmatprotec.2005.04.105

[5] A. Manna, B. Bhattacharyya, Taguchi and Gauss elimination method: A dual response approach for parametric optimization of CNC wire cut EDM of PRAlSiCMMC, Int J Adv Manuf Technol 28, 67–75, (2006).

DOI: 10.1007/s00170-004-2331-0

[6] Ting-Cheng Chang, Feng-Che Tsai, Jiuan-Hung Ke, Data mining and Taguchi method combination applied to the selection of discharge factors and the best interactive factor combination under multiple quality properties, Int J Adv Manuf Technol 31, 164–174, (2006).

DOI: 10.1007/s00170-005-0180-0

[7] S. S. Mahapatra, Amar Patnaik, Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method, Int J Adv Manuf Technol 34, 911–925, (2007).

DOI: 10.1007/s00170-006-0672-6

[8] Aminollah Mohammadi, Alireza Fadaei Tehrani, Ehsan Emanian, Davoud Karimi, A new approach to surface roughness and roundness improvement in wire electrical discharge turning based on statistical analyses, Int J Adv Manuf Technol 39, 64–73, (2008).

DOI: 10.1007/s00170-007-1179-5

[9] M.S. Phadke, Quality Engineering Using Robust Design, Prentice-Hall, Englewood Cliffs, NJ, (1989).

[10] L. Mingqi, L. Minghui, X. Guangyao, Study on the Variations of Form and Position of the Wire Electrode in WEDM-HS, Int J Adv Manuf Technol 25, 929–934, (2005).

DOI: 10.1007/s00170-003-1915-4

[11] P. Matoorian, S. Sulaiman, M.M.H.M. Ahmad, An experimental study for optimization of electrical discharge turning (EDT) process, journal of materials processing technology, 2 0 4, 350–356, (2008).

DOI: 10.1016/j.jmatprotec.2007.11.058

[12] Douglas C. Montgomery, Design and Analysis of Experiments, john wiley and sons (2001).

[13] Lloyd W. Condra, Reliability improvement with design of experiments, marcel dekker inc. (1993).