Abstract: In electrical discharge machining (EDM), a complete and clear theory has not yet been established. The developed theory (physical models) yields results far from reality due to the complexity of the physics. It is difficult to select proper parameter settings in order to achieve better EDM performance. However, modelling can solve this critical problem concerning the parameter settings. Therefore, the purpose of the present work is to develop mathematical model to predict performance characteristics of EDM on Ti-5Al-2.5Sn titanium alloy. Response surface method (RSM) and artificial neural network (ANN) are employed to develop the mathematical models. The developed models are verified through analysis of variance (ANOVA). The ANN models are trained, tested, and validated utilizing a set of data. It is found that the developed ANN and mathematical model can predict performance of EDM effectively. Thus, the model has found a precise tool that turns EDM process cost-effective and more efficient.
Abstract: Artificial neural networks (ANN) are used in distinct researching fields and professions, and are prepared by cooperation of scientists in different fields such as computer engineering, electronic, structure, biology and so many different branches of science. Many models are built correlating the parameters and the outputs in electrical discharge machining (EDM) concern for different types of materials. Up till now model for Ti-5Al-2.5Sn alloy in the case of electrical discharge machining performance characteristics has not been developed. Therefore, in the present work, it is attempted to generate a model of material removal rate (MRR) for Ti-5Al-2.5Sn material by means of Artificial Neural Network. The experimentation is performed according to the design of experiment (DOE) of response surface methodology (RSM). To generate the DOE four parameters such as peak current, pulse on time, pulse off time and servo voltage and one output as MRR are considered. Ti-5Al-2.5Sn alloy is machined with positive polarity of copper electrode. Finally the developed model is tested with confirmation test. The confirmation test yields an error as within the agreeable limit. To investigate the effect of the parameters on performance sensitivity analysis is also carried out which reveals that the peak current having more effect on EDM performance.
Abstract: Electrical discharge machining (EDM) is a relatively modern machining process having distinct advantages over other machining processes and can machine Ti-alloys effectively. The present study emphasizes the features of the development of regression equation based on response surface methodology (RSM) for correlating the interactive and higher-order influences of machining parameters on surface finish of Titanium alloy Ti-6Al-4V. The process parameters selected in this study are discharge current, pulse on time, pulse off time and servo voltage. Machining has been accomplished using negative polarity of Graphite electrode. Analysis of variance is employed to ascertain the adequacy of the developed regression model. Experiments based on central composite of response surface method are carried out. Scanning electron microscopy (SEM) analysis was performed to investigate the surface topography of the EDMed job. The results evidence that the proposed regression equation can predict the surface roughness effectively. The lower ampere and short pulse on time yield better surface finish.
Abstract: This paper deals optimized model to investigate the
effects of peak current, pulse on time and pulse off time in EDM performance on material removal rate of titanium alloy utilizing copper tungsten as electrode and positive polarity of the electrode. The experiments are carried out on Ti6Al4V. Experiments were
conducted by varying the peak current, pulse on time and pulse off time. A mathematical model is developed to correlate the influences of these variables and material removal rate of workpiece. Design of
experiments (DOE) method and response surface methodology
(RSM) techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through
analysis of variance (ANOVA). The obtained results evidence that as
the material removal rate increases as peak current and pulse on time
increases. The effect of pulse off time on MRR changes with peak ampere. The optimum machining conditions in favor of material removal rate are verified and compared. The optimum machining
conditions in favor of material removal rate are estimated and verified with proposed optimized results. It is observed that the developed model is within the limits of the agreeable error (about
4%) when compared to experimental results. This result leads to desirable material removal rate and economical industrial machining to optimize the input parameters.
Abstract: Conventionally the selection of parameters depends
intensely on the operator-s experience or conservative technological
data provided by the EDM equipment manufacturers that assign
inconsistent machining performance. The parameter settings given by
the manufacturers are only relevant with common steel grades. A
single parameter change influences the process in a complex way.
Hence, the present research proposes artificial neural network (ANN)
models for the prediction of surface roughness on first commenced
Ti-15-3 alloy in electrical discharge machining (EDM) process. The
proposed models use peak current, pulse on time, pulse off time and
servo voltage as input parameters. Multilayer perceptron (MLP) with
three hidden layer feedforward networks are applied. An assessment
is carried out with the models of distinct hidden layer. Training of the
models is performed with data from an extensive series of
experiments utilizing copper electrode as positive polarity. The
predictions based on the above developed models have been verified
with another set of experiments and are found to be in good
agreement with the experimental results. Beside this they can be
exercised as precious tools for the process planning for EDM.