Title: Optimisation of multiperformance characteristics in electric discharge machining of Aluminium Matrix Composites (AMCs) using Taguchi DOE methodology

Authors: Shankar Singh, Sachin Maheshwari, Poorn Chandra Pandey

Addresses: Division of Manufacturing Processes & Automation Engineering (MPAE), Netaji Subhas Institute of Technology, Dwarka, New Delhi - 110 078, India; Flat No. 22, Type – 4, NSIT Campus, Sec-3, Dwarka, New Delhi – 110 078, India. ' Division of Manufacturing Processes & Automation Engineering (MPAE), Netaji Subhas Institute of Technology, Dwarka, New Delhi – 110 078, India. ' 3/149, Vinay Khand, Gomti Nagar, Lucknow (UP), IIT, Roorkee, India; Asian Institute of Technology, Bangkok, Thailand

Abstract: This paper presents an investigation on the optimisation of process parameters for the Electric Discharge Machining (EDM) of 6061Al/Al2O3p/20p work specimens by employing the Taguchi Design of Experiment (DOE) methodology. One noise factor, aspect ratio (with two levels), and five control factors, viz. pulse current, pulse ON time, duty cycle, gap voltage and tool electrode lift time (three levels each), with an L18 (21 × 35) fractional factorial design were selected for the present experiment to obtain the optimal settings of factors and study their effects on multiple performance characteristics, namely, Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR). The experimental results were analysed by using Signal-to-Noise (S/N) ratios and Analysis of Variance (ANOVA). This analysis recognised the factors on the basis of their significant effect on the performance measures. The derived optimal levels were then used to conduct validation tests to confirm the effectiveness of this approach.

Keywords: electric discharge machining; EDM; electro-discharge machining; aluminium matrix composites; AMCs; Taguchi methods; design of experiments; DOE; orthogonal arrays; OA; signal-to-noise; S/N ratio; analysis of variance; ANOVA F-test; material removal rate; MRR; tool wear rate; TWR; surface roughness; optimisation; process parameters.

DOI: 10.1504/IJMR.2007.014640

International Journal of Manufacturing Research, 2007 Vol.2 No.2, pp.138 - 161

Available online: 21 Jul 2007 *

Full-text access for editors Access for subscribers Purchase this article Comment on this article