Si3N4-TiN rotary EDM optimization by Mo-Jaya algorithm with Pareto optimal solution, analysis of micro-structural and geometrical tolerances

Abstract

Research into rotary electrical discharge machining on high temperature with biomedical application Si3N4-TiN ceramic composite is presented in this paper. Current (I), pulse on time (Ton), pulse off time (Toff), dielectric pressure (DP), speed and spark gap voltage (Sv) are some of the many performance characteristics. Among the factors taken into account is the material removal rate, surface roughness, electrode wear rate, cylindricity, perpendicularity, top radial overcut, bottom radial over cut and run out. Multiple parameter combinations were validated experimentally and the resulting reactions were examined. Mean effects analysis and regression analysis are used to investigate the impacts of individual parameters. To comprehend the instantaneous behavior of the replies, multi-objective Jaya optimization is utilized to optimize the responses simultaneously. The multi-objective problem's outcomes are shown in 3D charts, with each showing the Pareto optimal solution. From this real conclusion, the optimal combinations of answers are extracted and reported. The aggregate optimization result was also shown, which factored in all eight responses. MRR of 0.238 g/min was obtained which is a 10.6% improvement from the experimental values. Electrode wear of 0.0028 g/min was obtained showing a 6.6% reduction. Similarly reduction in values of Surface roughness, top radial overcut and bottom radial over cut, Circularity, Perpendicularity, run out was observed and the percentages are 3.4, 4.7, 4.5, 7.8, 10.0 and 10.53 respectively. Details on the structural and morphological examinations of the various surface abnormalities that occur during the process have been presented.