Applied Mechanics and Materials Vols. 766-767

Abstract: In this paper , the parameters of Electrical Discharge Machine (EDM) are investigated during the machining of Inconel 718 by using different sizes of circular Aluminum electrode. Demand for better surface finishes are increasing recently for all materials, the low rigidity and high material removal rate of Inconel alloys offers a challenging task in obtaining better Surface Finish. The analysis of surface characteristics like Surface Roughness (SR) of Inconel 718 material is carried out an excellent surface finish can be obtained by setting the machining parameters at optimum level. Experimentation was carried out by using Taguchi’s L₉ orthogonal array under different conditions of parameters. The response of SR is considered for improving the machining efficiency. Optimal combination of parameters was obtained Taguchi Optimization technique. The confirmation experiments results shows that the significant improvement in Surface Finish was obtained. ANOVA have been used to analyze the contribution of individual parameters on Surface Roughness. The experimental result demonstrates that the Taguchi method satisfies the practical requirements.

Abstract: Wire-electro discharge machining (WEDM) is one of the important non-traditional machining processes used to machine difficult-to-machine materials and complicated profiles. Being a high degree of complexity process, it is unfavourable to determine optimal parameters for improving cutting performance. Metal removal rate and surface finish are most important response parameters, which decide the performance on cutting. The single optimal combination of cutting parameters is not there, as their influences on the metal removal rate and the surface finish are quite the opposite. In the present study, a multiple regression model is used to represent relationship between input and output variables and the parameters were optimized based on response surface metho dology (RSM).

Abstract: Grinding is an abrasive machining process which controls the surface finish of the materials in production of industrial components at the end stage. During the grinding process, wheel gets loaded with swarf and this loading will affect the cutting ability of the wheel and also the surface finish of the job. Hence the grinding wheel is to be dressed at appropriate time intervals and for necessary time duration. At present, the monitoring of grinding wheel loading and dressing is done by the operator i.e., the frequency of dressing and duration of dressing is determined by the operator based on his experience. Hence there arises a need to develop a systematic approach to this problem which can monitor the process and if not accurately should at least produce a realistic estimate of the percentage of wheel loading, frequency of dressing and duration of dressing. In machine vision system, Shutter speed is an important factor which will affect the image quality. Hence, in this work, attempts are made to monitor wheel loading using a low cost-high speed camera with variable shutter speed and the shutter speed is optimized for the better image quality.

Abstract: Friction welding is widely used in determining the mass production process for joining dissimilar materials due to its environment friendliness, production efficiency and low heat input. In this study, Taguchi approach was applied in grey relational analysis to solve the multi-response optimization. The experimental result analysis is to achieve the maximization of tensile strength and minimization of weld time and metal loss. The optimal combinations of welding parameters are predicted through grey relational analysis for the multi-performance and optimal results were verified through confirmation test.

Abstract: Friction welding is a solid state process used mostly for joining dissimilar materials due to mass production with less time consuming. The aim of this work is to study the dissimilar joints of austenitic stainless steel and copper for evaluating the impact strength. The experiment is conducted by using Taguchi’s L₉ orthogonal array for determining the value of impact strength. The input parameters such as friction pressure, upset pressure, rotational speed and burn-off length were considered and the optimum process parameter was determined based on the response of impact strength. The predicted value of impact strength was validated by conducting the confirmation run using optimum parameters. The analysis of variance (ANOVA) is conducted for the mean of impact strength.

Abstract: Linear layout is the commonly major preferred arrangement of the flexible manufacturing systems (FMS). The proposed enhanced sheep flock heredity algorithm to solving the unequal area linear layout problem through the real case study problem. The proposed model is to minimize the transportation cost with non-overlapping. Computational results show that proposed sheep flock heredity algorithm (SFHA) can obtain better than particle swarm optimization (PSO) and existing method.

Abstract: Wire electrical discharge machining is one of the important non-traditional machining processes for machining difficult to machine materials. It involves the removal of material by the discrete electric discharges produced between the inter electrode gap of continuously moving wire electrode and the work piece. The ability to produce intricate profiles on materials irrespective of the mechanical properties made this process to be widely used in industries. The present study investigates the relationship of various process parameters in WEDM of AISI 202 stainless steel with brass electrode.The experiments were planned according to Taguchi’s L18 orthogonal array and experimental models were developed. The important process parameters identified for the present study were pulse on time, peak current, pulse off time, wire feed, wire tension, dielectric flushing pressure, servo feed and gap voltage. The surface roughness of the machined surface was measured as the process performance measure. Analysis of variance test has also been carried out to check the adequacy of the developed models and to identify the level of significance of each process parameters. In addition to the developed models, ABC optimization has been performed to identify the optimum parameter combination for minimum surface roughness and the obtained optimal process parameters are peak current 11 A, pulse on time 100 μs, pulse off time 49 μs, wire feed 4 m/min, wire tension 10 N, flushing pressure 12 kg/cm², servo feed 2100 mm/min and set gap voltage 30 V. Finally the results were verified with the experimental results and found that they are in good agreement.

Abstract: Electrical-discharge Machining (EDM) is a nonconventional machining process utilizing an electric spark discharge from the electrode (-) towards the work piece (+) through the dielectric fluid. The Dimensional accuracy in this is very important consideration for the accuracy of the finished product. The objective of this experimental study is to determine parameters that offer the best dimensional accuracy in electrical discharge machining (EDM). Discharge current (A), Pulse On Time (T_on), Pulse Off Time (T_off ) and Circle,Rectangle,Triangle and Square Tool Geometrical Shapes (Geo) are taken as machining parameters. The experimental investigations are carried out on Monel 400 material using Tungsten copper electrode. The response of ROC is considered for improving the machining efficiency. Optimal combination of parameters was obtained Taguchi Optimization technique. The confirmation experiments results shows that the significant improvement in Radial Overcut was obtained. ANOVA have been used to analyze the contribution of individual parameters on ROC. The experimental result demonstrates that the Taguchi method satisfies the practical requirements

Abstract: In the modern competitive scenario in manufacturing industries, producing products with low cost, less time and good quality are the ultimate goal of any manufacturer. To achieve the goal, several optimization tools are developed to optimize the process parameters of the machining process. Turning is one of the machining processes that cannot be avoided in any manufacturing industries. In this review, optimization of process parameters in turning process by computational intelligence (CI) paradigms for the past ten years is studied. Optimization by CI paradigms such as Fuzzy System (FS), Evolutionary Computation techniques Genetic Algorithm (GA), Swarm Intelligence including Particle Swarm Optimization (PSO), Ant Colony Optimization (ACO), Artificial Neural Networks (ANN) etc., is considered. In turning process, surface roughness, tool wear, production time and cost are optimized.

Abstract: In this investigation, an attempt using data envelopment analysis based Taguchi method, is involved in solving the multi-response optimization of the process parameters of rotational speed, transverse speed, tool tilt angle with different tool pin profiles on the stir zone evolution in AA8011 Aluminium alloys. Three different tool pin profiles (hexagonal, pentagonal pin profiles of High Carbon High Chromium steel and Hexagonal tool pin profile of H13 steel) have been used to make the joints at the different combination of process parameters using L₉ orthogonal array. The Vickers hardness and Impact strength are measured to optimize the process parameters using DEA based Taguchi method. It is found that the optimum conditions of rotational speed 660 RPM, transverse speed of 30 mm per minute and tilt angle of 2 degrees with the hexagonal tool pin profile of High Carbon High Chromium steel yielded a good quality weld.