Title: Parametric optimisation of electrical discharge machining process: a numerical approach

Authors: Chinmaya P. Mohanty; Siba Sankar Mahapatra; Jambeswar Sahu

Addresses: Department of Mechanical Engineering, National Institute of Technology, Rourkela, 769008, India ' Department of Mechanical Engineering, National Institute of Technology, Rourkela, 769008, India ' Department of Mechanical Engineering, National Institute of Technology, Rourkela, 769008, India

Abstract: In this work, a thermal model based on finite element method has been proposed to predict the material removal and tool wear in electrical discharge machining process by simulating a single spark discharge. The model is validated by conducting experiments on a die-sinking EDM machine. It is found that numerical model provides reasonably accurate estimation of responses. Parametric analysis is conducted on the proposed model to study the influence of significant process parameters on the responses. Regression analysis is carried out to develop empirical models relating responses with process parameters. Finally, a non-dominated sorting genetic algorithm has been employed to obtain Pareto optimal solution for multi-objective optimisation. The numerical method provides an inexpensive and time saving alternative to study the performance of machining before actual cutting operation.

Keywords: electrical discharge machining; EDM; numerical simulation; response surface methodology; RSM; finite element method; FEM; non-dominated sorting genetic algorithm; NSGA; parametric optimisation; electro-discharge machining; thermal modelling; material removal rate; MRR; tool wear; single spark discharge.

DOI: 10.1504/IJISE.2016.073963

International Journal of Industrial and Systems Engineering, 2016 Vol.22 No.2, pp.207 - 244

Available online: 26 Dec 2015 *

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