Effect and Optimization of Machine Process Parameters on MRR for EN19 & EN41 materials using Taguchi

(BQ) The present work deals with the comparison of the MRR for EN19 and EN41 material in a die sinking EDM machine. The various input factors like Pulse ON time, Pulse OFF time, Discharge current and voltage were considered as the input processing parameters, while the MRR is considered as the output. Optimization using Taguchi method was performed to predict the best combination of inputs towards maximum output. A comparison was done to obtain the effect of these input parameters over the MRR for both the material, and simultaneously the impact of the carbon percentage over the MRR was investigated.
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Effect and Optimization of Machine Process Parameters on MRR for EN19 & EN41 materials using Taguchi Available online at www.sciencedirect.com ScienceDirect Procedia Technology 14 (2014) 204 – 210 2nd International Conference on Innovations in Automation and Mechatronics Engineering, ICIAME 2014 Effect and Optimization of Machine Process Parameters on MRR for EN19 & EN41 materials using Taguchi tool steel Vikasa, Shashikanta, A.K.Royb and Kaushik Kumarb* b a Research Scholar, Department of Mechanical Engineering, Birla Institute of Technology, Mesra, Ranchi, 835215, India Associate Professor, Department of Mechanical Engineering, Birla Institute of Technology, Mesra, Ranchi, 835215, India Abstract The present work deals with the comparison of the MRR for EN19 and EN41 material in a die sinking EDM machine. The various input factors like Pulse ON time, Pulse OFF time, Discharge current and voltage were considered as the input processing parameters, while the MRR is considered as the output. Optimization using Taguchi method was performed to predict the best combination of inputs towards maximum output. A comparison was done to obtain the effect of these input parameters over the MRR for both the material, and simultaneously the impact of the carbon percentage over the MRR was investigated. It was found that the Discharge current in case of the EN41 material and EN19 material had a larger impact as compare to other processing parameters on the MRR. A relative study of the carbon composition for both the material was also done. © 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license © 2014 The Authors. Published by Elsevier Ltd. (http://creativecommons.org/licenses/by-nc-nd/3.0/). Selection and/or peer-review under responsibility of the Organizing Committee of ICIAME 2014. Peer-review under responsibility of the Organizing Committee of ICIAME 2014. Keywords: EN19, EN41, EDM, MRR,Taguchi, Design of Experiments, Optimization * Corresponding author. Tel.: +91-9431597463. E-mail address: kkumar@bitmesra.ac.in 1. Introduction In an EDM process, choosing the correct parameter for finding out the Optimized value of MRR is very important. Different input parameters like Pulse-ON time, Pulse-OFF time, Discharge current and Voltage affects the MRR for both EN19 and EN41 material in a different manner. Apart from these input parameters, there are many other parameters, which affect the MRR differently. They may be flushing pressure, feed rate, etc. A lot of work has been carried out in this field for the optimization of the MRR with different materials and in the presence of different 2212-0173 © 2014 Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/). Peer-review under responsibility of the Organizing Committee of ICIAME 2014. doi:10.1016/j.protcy.2014.08.027 Vikas et al. / Procedia Technology 14 (2014) 204 – 210 methods. Vikas et al (2013) carried out the optimization of the MRR for EN41 material based on the 4 input parameters like the pulse on time, pulse off time, discharge current and gap voltage. He found out that the current along with the pulse-off time had a larger impact over the MRR followed by some of the interaction plot, while the affect of the other parameters were negligible. Kamal Hassan et al (2012) carried out the same optimization technique using Taguchi to optimize the MRR for medium brass alloy in CNC turning machine. He used the various input parameters like cutting speed, depth of cut, feed, etc to optimize the MRR. He found that the cutting speed and the feed rate had significant effect over the MRR followed by their interaction. He found that the cutting speed and the feed rate had direct effect over the MRR, as they increased directly with them. Similarly, Kuldeep ojha et al (2010) and AKM Asif Iqbal et al (2010) also carried out the improvement of the MRR on the different input parameters. Many researcher (Bhaduri et al (2009), Belgassim and Abusada (2012), Ikram et al (2013), Natrajan and Arunachalam (2011), Tiwari (2013), Sanchez et al (2002), Singh et al (2004), Kurnia et al (2008), Jahan et al (2009), and Antony (2001)) have worked with different materials and on different non conventional machines using different parameters to obtain most optimized value in order to economize the outputs. Nomenclature C1 C2 C3 C4 A B C D Pulse-On time for EN19 material Pulse-Off time for EN19 material Discharge Current for EN19 material Voltage for EN19 material Pulse-On time for EN41 material Pulse-Off time for EN41 material Discharge Current for EN41 material Voltage for EN41 material 2. Experimental Setup The entire experiment was carried on a Die sinking EDM machine (Electronica EMT-43 Machine). Experiment was performed individually for both the materials one after another. The work-piece on which the EDM process was carried out was EN19 and EN41 material of cylindrical crossTool for EDM operation was a rectangular positive polarity Copper of dimension 25x25mm. Paraffin oil was selected as the dielectric medium. First of all the initial weight of the work-piece was taken before carrying out the EDM operation. The final weight was then compared with the initial weight and the difference of the two weights yield the MRR for the EN material. The experiment was carried out according to the design of experiment table generated by the taguchi design of experiments. For each set of experiments, the value of all the 4-input parameters were made constant and accordingly, the material removal was carried out in the EDM machine. The process was repeated for all the 27 experiments. The percentage composition of the different elements were obtained by Energy Dispersive X-Ray Spectroscopy (EDX) (JSM 63901v, Resolution=3nm at 30kV at high vaccum mode and 4nm at 40 kV low vaccum mode). The numbers of levels are selected by dividing the total ...