Mathematical and MATLAB based process optimization by simulated annealing algorithm for wire electrical discharge machining of EN31

Abstract

The inevitability to machine hard materials and intricate shapes that are hard to be worked by traditional methods have stressed the need for non-traditional manufacturing processes specifically Wire Electro Discharge Machining (WEDM). WEDM encompasses intricate processes that include heating as well as cooling. The working parameters include pulse on time, pulse off time, table feed rate, flushing pressure, wire tension, wire velocity etc. has to be preferred suitably so that an optimized result can be attained. A single constraint has been chosen for the purpose of optimization to maximize the Metal Removal Rate (MRR). In this work a gear was machined out of EN31 material using the WEDM process and the process parameters such as pulse on time, peak current, wire feed rate and machining speed have been optimized using Simulated Annealing Algorithm and also using MATLAB based optimization. Simulated Annealing (SA) based optimization has been established to optimize the parameters in order to improve MRR. The objective function for metal removal rate is obtained based on the mathematical model.