Abstract
In the present research, the AZ31 alloy is machined by wire-cut electric discharge machining (WEDM). The experiments were designed according to the Box-Behnken design (BBD) of response surface methodology (RSM). The input process variables, namely servo feed (SF), pulse on-time (Ton), servo voltage (SV), and pulse off-time (Toff), were planned by BBD, and experiments were performed to investigate the cutting rate (CR) and recast layer thickness (RCL). The analysis of variance (ANOVA) was performed to determine the influence of machining variables on response characteristics. The empirical models developed for CR and RCL were solved using Multi-Objective Particle Swarm Optimization (MOPSO). Pareto optimal front is used for the collective optimization of CR and RCL. The optimal solution suggested by the hybrid approach of RSM-MOPSO is further verified using a confirmation test on the random setting indicated by the hybrid algorithm. It is found that the minimum RCL (6.34 µm) is obtained at SF: 1700; SV: 51 V; Toff: 10.5 µs; and Ton: 0.5 µs. However, maximum CR (3.18 m/min) is predicted at SF: 1900; SV: 40 V; Toff: 7 µs; and Ton: 0.9 µs. The error percentage of ±5.3% between the experimental results and predicted solutions confirms the suitability of the proposed hybrid approach for WEDM of AZ31.
Highlights
wire-cut electric discharge machining (WEDM) is a non-traditional machining technique that can effectively generate intricate shapes from conductive materials [1]
The summary of analysis (Table 5) shows that the Toff and Ton exhibit p-values less than 0.05, due to which these are categorized as influential process variables for cutting rate (CR)
The surface morphology of AZ31 alloy machined at WEDM (SF: 1830; servo voltage (SV): 42 V; Toff: 7 μs; Ton: 0.9 μs) is studied by Jeol make SEM
Summary
WEDM is a non-traditional machining technique that can effectively generate intricate shapes from conductive materials [1]. WEDM is a thermal-erosion process [2], where localized heating is utilized to remove the material, which is caused due to plasma channel. Plasma is produced between the workpiece and electrode [3]. A fraction of the heat from the total produced is transferred to the workpiece to melt the material and evaporate it, which is further fleshed out while utilizing de-ionized fluid flowing. A carter is left on the machined surface [4]. In WEDM, a discharge cycle with very short Toff and
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