Optimization of EDM Parameters in Machining AISI D3 Tool Steel by Grey Relational Analysis

Abstract:

This study presents optimization of multiple performance characteristics [material removal rate (MRR), surface roughness (Ra), and overcut (OC)] of hardened AISI D3 tool steel in electrical discharge machining (EDM) using Taguchi method and Grey relational analysis. Machining process parameters selected were pulse current I_p, pulse-on time T_on, pulse-off time T_off and gap voltage V_g . Based on ANOVA, pulse current is found to be the most significant factor affecting EDM process. Optimized process parameters simultaneously leading to a higher MRR, lower Ra, and lower OC are then verified through a confirmation experiment. Validation experiment shows an improved MRR, Ra and OC when Taguchi method and grey relational analysis were used.

• Periodical: Applied Mechanics and Materials (Volume 330)
• Pages: 747-753
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.330.747
• Online since: June 2013
• Authors: Othman Belgassim, Abdurahman Abu-Saada
• Keywords: EDM, Grey Relational Analysis (GRA), Multiple Performance Characteristics, Taguchi Method

References

[1] Yang X, Guo J, Chen X & Kunieda M, Molecular dynamics simulation of the material removal mechanism in micro-EDM, Precision Engg, 35 (2011) 51-57.

DOI: 10.1016/j.precisioneng.2010.09.005

[2] Aligiri E, Yeo S H & Tan P C, A new tool wear compensation method based on real-time estimation of material removal volume in micro-EDM, J Mater Process Tech., 210 (2010) 2292-2303.

DOI: 10.1016/j.jmatprotec.2010.08.024

[3] Mandal, D., Pal, S. K., and Saha, P. Modeling of electrical discharge machining process using back propagation neural network and multi-objective optimizations using non-dominating sorting genetic algorithm: II. J. Mater. Process. Technol., 2007,186(1–3), 154–162.

DOI: 10.1016/j.jmatprotec.2006.12.030

[4] Phadke M S, Quality Engineering using Robust Design (Pearson Education, Singapore) 2008.

[5] Ross P J, Taguchi Techniques for Quality Engineering (McGraw- Hill, New Delhi) 2005.

[6] Taguchi G, Introduction to Quality Engineering (Asian Productivity Organization, Tokyo) 1990.

[7] Gopalsamy B M, Mondal B & Ghosh S,Taguchi method and ANOVA: An approach for process parameters optimization of hard machining while machining hardened steel, J Sci Ind Res, 68 (2009) 686-695.

[8] Deng J, Introduction to grey system, J Grey Syst, 1 (1989) 1-24.

[9] Patel K M & Pandey Pulak M & Venkateswara Rao P, optimization of process parameters for multi-performance characteristics in EDM of Al2O ceramic composite , Int J Adv Manuf Technol, 47 (2010) 1137-1147.

DOI: 10.1007/s00170-009-2249-7

[10] Zhu F, Yi M, Ma L & Du J, The grey relational analysis of the dielectric constant and others, J Grey Syst, 8 (1996) 287-290.

[11] Tan X, Yang Y & Deng J, Grey relational analysis factors in hypertensive with cardiac insufficiency, J Grey Syst, 10 (1998) 75-80.

[12] Jangra K, Jain A & Grover S, Optimization of multiple machining characteristics in wire electrical discharge machining of punching die using Grey relational analysis, J Sci Ind Res, 69 (2010) 606-612.

[13] J.L. Deng, "Introduction to Grey system," J. Grey Syst.,vol.1, p.1–241989.

[14] J. Deng, "A Course on Grey System Theory," HUST Press, Wnhan,China, 1990.