Int. J. of Industrial and Systems Engineering   »   2014 Vol.18, No.2

 

 

Title: Modelling and optimisation of travelling wire electro-chemical spark machining process

 

Authors: Basanta Kumar Bhuyan; Vinod Yadava

 

Addresses:
Mechanical Engineering Department, Motilal Nehru National Institute of Technology Allahabad, Allahabad-211004, Uttar Pradesh, India
Mechanical Engineering Department, Motilal Nehru National Institute of Technology Allahabad, Allahabad-211004, Uttar Pradesh, India

 

Abstract: This paper presents modelling and optimisation of cut quality during a self developed travelling wire electro-chemical spark machining (TW-ECSM) process. In the present study, four input process parameters such as applied voltage, electrolyte concentration, wire feed velocity and workpiece thickness and two output parameters such as surface roughness (Ra) and material removal rate (MRR) are considered. The hybrid approach comprising of Taguchi methodology (TM) and response surface methodology (RSM) is used for modelling whereas multi-objective optimisation is performed using hybrid approach of TM and grey relational analysis (GRA) coupled with entropy measurement methodology. The approach first uses the Taguchi quality loss function to find the optimum level of input parameters. This optimum input parameter values are further used as the central values in the RSM to develop the second-order response model. The entropy measurement methodology is employed for the calculation of weight corresponding to each quality characteristic. The results have been observed that in comparison to TM, the hybrid approach enhances MRR by 117% and reduces the Ra by 10%.

 

Keywords: travelling wire electrochemical spark machining; TW-ECSM; Taguchi methods; response surface methodology; RSM; grey relational analysis; GRA; entropy measurement methodology; wire ECM; electrochemical machining; modelling; optimisation; applied voltage; electrolyte concentration; wire feed rate; workpiece thickness; surface roughness; surface quality; material removal rate; MRR.

 

DOI: 10.1504/IJISE.2014.064703

 

Int. J. of Industrial and Systems Engineering, 2014 Vol.18, No.2, pp.139 - 158

 

Available online: 04 Sep 2014

 

 

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