An Accelerated Particle Swarm Optimization Algorithm on Parametric Optimization of WEDM of Die-Steel

Abstract

This study employed Accelerated Particle Swarm Optimization (APSO) algorithm to optimize the machining parameters that lead to a maximum Material Removal Rate (MRR), minimum surface roughness and minimum kerf width values for Wire Electrical Discharge Machining (WEDM) of AISI D3 die-steel. Four machining parameters that are optimized using APSO algorithm include Pulse on-time, Pulse off-time, Gap voltage, Wire feed. The machining parameters are evaluated by Taguchi’s L9 Orthogonal Array (OA). Experiments are conducted on a CNC WEDM and output responses such as material removal rate, surface roughness and kerf width are determined. The empirical relationship between control factors and output responses are established by using linear regression models using Minitab software. Finally, APSO algorithm, a nature inspired metaheuristic technique, is used to optimize the WEDM machining parameters for higher material removal rate and lower kerf width with surface roughness as constraint. The confirmation experiments carried out with the optimum conditions show that the proposed algorithm was found to be potential in finding numerous optimal input machining parameters which can fulfill wide requirements of a process engineer working in WEDM industry.