Effect and Optimization of various Machine Process Parameters on the Surface Roughness in EDM for an EN41 Material using GreyTaguchi

(BQ) The article presents an idea about the effect of the various input process parameters like Pulse ON time, Pulse OFF time,Discharge Current and Voltage over the Surface Roughness for an EN41 material. Here, 5 different output parameters concernedwith surface roughness like Ra, Rq, Rsk, Rku and Rsm are taken and optimized accordingly, using the Grey-Taguchi method.
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Effect and Optimization of various Machine Process Parameters on the Surface Roughness in EDM for an EN41 Material using GreyTaguchiAvailable online at www.sciencedirect.comScienceDirectProcedia Materials Science 6 (2014) 383 – 3903rd International Conference on Materials Processing and Characterisation (ICMPC 2014)Effect and Optimization of various Machine Process Parameters onthe Surface Roughness in EDM for an EN41 Material using Greytool steelTaguchiVikasa, Apurba Kumar Royb, Kaushik Kumarb*baResearch Scholar, Birla Institute of Technology, Mesra, Ranchi-835215, INDIAAssociate Professor, Birla Institute of Technology, Mesra, Ranchi-835215, INDIAAbstractThe article presents an idea about the effect of the various input process parameters like Pulse ON time, Pulse OFF time,Discharge Current and Voltage over the Surface Roughness for an EN41 material. Here, 5 different output parameters concernedwith surface roughness like Ra, Rq, Rsk, Rku and Rsm are taken and optimized accordingly, using the Grey-Taguchi method. TheGrey-Taguchi method used in the article considers an L27 orthogonal array, which uses a different combination of the 4-inputparameters to obtain an optimized value of the surface roughness for EN41 material. The 5 different output values of the surfaceroughness are calibrated into a single value (i.e. Grade) by calculating their normalized, Δ and ξ values .On the basis of theirGrade, the S/N ratio is obtained and accordingly the ANOVA table is generated. It was found that the Current had larger impactover the Surface Roughness value, followed by the Voltage. The experimental results thus, obtained were compared with thetheoretical results and they were found very close to one another.© 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/). the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET).Selection and peer-review under responsibility ofSelection and peer review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET)Keywords: EN41; EDM; Surface Roughness;Grey-Taguchi.1. INTRODUCTIONThe existence of the increased competition among the different countries to meet the technological advances andthe creation of the new and different military equipments, led to the creation of different hard materials which were* Corresponding author. Tel.: +91-9431597463; fax: 0651-2275444.E-mail address :kkumar@bitmesra.ac.in2211-8128 © 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/).Selection and peer review under responsibility of the Gokaraju Rangaraju Institute of Engineering and Technology (GRIET)doi:10.1016/j.mspro.2014.07.049384Vikas et al. / Procedia Materials Science 6 (2014) 383 – 390difficult to machine. To meet these growing advances, it was very much necessary to create certain machiningequipments, which can be easily used to machine such materials. This very requirement was met during the 2ndworld war, as indicated by E. C. Jameson (2001), by the USSR and USA individually, by the development of theElectro-Discharge machine (EDM). The EDM machine since then has got continuously modified to control theamount and the direction of sparks produced from the EDM machine. The EDM machine consists of a closedchamber, where the continuous spark is used to machine the work-piece material in the presence of a suitabledielectric medium, usually Paraffin oil. The work-piece i.e. EN41 material is of positive polarity, while the tool i.e.copper is of negative polarity.The Surface Roughness plays a very important role for any manufacturing work in order to identify the extent ofthe surface finish with reference to time and cost. A number of experimental works has been carried out till date forthe investigation of the effect of the different parameters over the surface roughness value for different materials.B.Jabbaripour et al (2012) carried out an investigation over the effect of pulse current, pulse on time and open circuitvoltage over the surface roughness for Ti-6Al-4V alloy material. They found out that the Pulse current and the PulseOn time had larger significance over the surface roughness. Another investigation was carried out by M.K. Das et al(2013) to find out the effect of different input parameters over the MRR and surface Roughness in EDM using theWPCA approach. It was found out that the Current followed by the Voltage had larger impact over the multioptimization of MRR and surface roughness. Another approach regarding the surface roughness optimization wascarried out by S Aravind Krishnan et al (2012) to optimize MRR and Surface roughness in wire Electrical dischargeturning operation using artificial neural network approach. Pulse of ti ...