Higher MRR Research Articles

Experimental Investigations and Optimum Performance Evaluation of Wire-EDM Characteristics of Aluminium 6061-Magnesite Composites

It is essential to determine the most suitable machining method for magnesite-reinforced Aluminium 6061 composites, which possess excellent mechanical properties, especially notable tensile strength and hardness. The composites were produced using a stir-casting technique, incorporating reinforcements of lightly-calcined magnesite, dead burnt magnesite, and waste magnesite in weight fractions of 2.5%, 5%, and 7.5% within an aluminium 6061 matrix. Wire electrical discharge machining was employed to investigate the machining characteristics of these composites, using controllable process parameters such as cutting speed, pulse-on and pulse-off times, and the weight fraction of magnesites. Two performance indicators such as surface roughness and material removal rate were tested for various parameter combinations by central composite design. To comprehend the impact of the study parameters, contour charts were drawn. MRR increases at a high cutting speed of 2 mm/min when the pulse-on time changes from 120 μs to 125 μs. SR increases when the pulse-on times above 120 μs at all cutting speeds. High cutting speeds make high MRR irrespective of the weight fractions of reinforcement. High pulse-on times make the material melt more, which increases the material removal rate. Because specimen surface material erodes quickly and forms microcracks, high pulse-on time also results in high surface roughness. To optimize the WEDM machining conditions for each composite, hybrid SSO-DF and DFO-DF optimizers were developed by combining the desirability function with Salp-swarm optimization and Dragonfly optimization algorithms. The cutting speed of 2 mm/min and the pulse-on time of 114 μs produce the best performances on the composites.

Influence of Cryogenic Coated Copper Tool Electrode in Electrochemical Micro Machining process of Stainless Steel 316

Electrochemical micro-Machining (ECMM) is best suited for machining micro level profiles as it provides several advantages like better precision, less wear and machinability of wide range of materials. Using various levels of process parameters like voltage, electrolyte concentration, frequency and duty cycle, electrochemical micro machining was performed using untreated and cryogenic treated electrodes and its effect on various response parameters while machining Stainless Steel 316 are studied. From results obtained, the cryogenic treated tool electrode had a high MRR,9.8% of lower overcut,11.2 % of lower conicity and 3.8% of higher circularity compared to untreated tool electrode because the treated tool has high electrical conductance, high corrosion resistance and smaller grain size. The optimized values for Cryogenic Treated tool was achieved when applied voltage was 10V, electrolyte concentration was 30 g/L, frequency was 50 Hz and duty cycle was 33%.

TAGUCHI-GREY OPTIMIZATION OF SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE ON ELECTRO-DISCHARGE MACHINING OF NOVEL AA7075-TiO2 METAL MATRIX COMPOSITE USING WASTE CORNCOB BIOSILICA DIELECTRICS

In this study, a novel AA7075-TiO2 metal matrix composite was machined utilizing a biosilica mixed EDM technique and the surface roughness and material removal rate are optimized. The biosilica particles are produced from waste maize cobs and then silane-treated. The optimization of process variables wasperformed using Taguchi grey relational approach with a process variable of peak current, gap voltage and pulse-on time. Results revealed that the gap voltage is the most important process variable, since it has a larger max-min difference of 0.25. In order to create a high MRR of 11.6[Formula: see text]mm3/min and a surface roughness of 2.25 m, the maximum GRG of 0.79 for Trial 1 (A2B1C3) represents the most ideal process variable group. The best results appear to be obtained with a peak current of 10 A, a gap voltage of 20[Formula: see text]V, and a pulse-on time of 140[Formula: see text][Formula: see text]s. The new GRG, however, is around 2.51% better than the anticipated optimized process variables of A2B1C3 with an old GRG of 0.79, according to the confirmation research. The new MRR of 11.89[Formula: see text]mm3/min and the surface roughness of 2.30[Formula: see text]s with a GRG of 0.81 are based on the optimized new process variables (A1B1C3).

Effect of Deficit Irrigation on Wheat (Triticum aestivum L.) Yield and Water Use Efficiency in the Semi-Arid Region of Awash Basin, Ethiopia

Crop production is largely limited by water availability in arid and semi-arid regions of Ethiopia. Changing climate conditions and declining water resources demand appropriate approaches to improve crop yield and water use efficiency through a reduced and more reliable water supply. A field experiment was conducted to evaluate the effect of limited irrigation water use on bread wheat production and water use efficiency under the semi-arid climate conditions of Awash basin of Ethiopia. Five irrigation levels, that is, full irrigation (100% ETc/control), 85% ETc, 70% ETc, 55% ETc, and 40% ETc, were evaluated using a randomized complete block design (RCBD) with four replicates. Statistical analysis has shown a significant effect of irrigation levels on wheat grain yield, water use efficiency, economic profit, wheat grain quality, and aboveground biomass. The highest grain yield (5,085 kg ha−1) was obtained from 100% ETc irrigation application (i.e. 417.2 mm of water), and the lowest grain yield was obtained from 40% ETc (i.e. 223.7 mm of water) application. A deficit level of 85% ETc resulted in a yield that was comparable to that of full irrigation. Compared to other treatments, the 70% ETc application produced the highest water use efficiency (1.42 kg m−3). Using the saved water obtained from 70% ETc deficit irrigation application, 23.4% more wheat could be produced on 1.38 ha of land, resulting in the highest profit (US$2,563.9) and higher MRR (137%). The yield response factor and crop-water production function indicated that maintaining irrigation at optimal levels can prevent potential yield reductions. Consequently, a 70% ETc deficit irrigation application was found to be optimal for increasing wheat grain yield, water use efficiency, and economic benefits from irrigated wheat production. These results suggest that deficit irrigation for wheat under semi-arid climatic conditions is a viable irrigation management option for enhancing water use efficiency.

Performance analysis of ECMM using saw, critic and ANN methods

Electrochemical micromachining (ECMM) finds application in various industries especially in surface finishing process in aerospace industries. In this research the workpiece made from aluminum scrap metal matrix reinforced with alumina is subjected to wear, surface profile and machinability studies. To analysis the ECMM performance simple additive weighting (SAW) CRiteria Importance Through Intercriteria Correlation (CRITIC) and Artificial Neural Network (ANN) was used. The wear studies show that at high loads the height wear loss is less and frictional force is more. The L18 mixed orthogonal array experiments was conducted and analysis of experiments shows that the most crucial parameter values for high MRR and low OC are 28g/lit NaNO3+0.05M HNO3, 10 V, and 80% duty cycle. The weight values of the performance metrics obtained using SAW method are 0.549 and 0.45. The optimal output performance predicted by ANN is MRR of 0.520 ?m/sec and OC of 23.8 ?m.

Effect of Plant Density and NPS Fertilizer Rates on Growth, Yield and Yield Components of Maize (Zea mays L.) in Central highland of Ethiopia

Maize is an important cereal crop in Ethiopia due to its use as a source of food security. However, its productivity is limited by insufficient application of the NPS fertilizer and inappropriate plant density. A field experiment was conducted during 2020 and 2021 cropping seasons at Liban Jawi and Toke Kutaye districts of West Shoa Zone, Ethiopia to study the effect of plant density and NPS fertilizer rates on growth, yield, and yield components of maize. The experiment consisted of three plant populations (53,300, 66,600 and 88,800 plants ha-1) and five NPS fertilizer rates (100, 150, 200, 250 and 300 kg NPS ha-1) laid out in a randomized complete block design with three replications. The results showed that plant height, ear height and biological yield increased with increasing plant density. On the contrary ear length, number of grains per row, grain yield and harvest index decreased with increasing plant density. Plant density of 53,300 plants ha-1 produced the higher grain yield (5969 kgha-1) compared to that of 88,800 plants ha-1 (5175 kg ha-1). However, grain yield at 53,300 plants ha-1 did not show a significant difference with that of 66,600 plants ha-1 (5746 kg ha-1). In case of NPS fertilizer rates the results showed that plant height, ear height, ear length, number of grains per row, 1000 seed weight, biological yield, grain yield and harvest index increased with increasing NPS fertilizer rates up to optimum rate. Fertilizer application of 200kg NPS ha-1 produced a higher grain yield (6710 kg ha-1). The highest economic (126,423 Birr ha-1) and a higher MRR (2630%) resulted from the application of 200 kg NPS ha-1 with a plant population of 53,300 plants ha-1. Therefore a Plant density of 53,300 plants ha-1 and a blended fertilizer application with 200 kg NPS ha-1 was the most appropriate for highland maize in the study area.

Optimization with artificial intelligence of the machinability of Hardox steel, which is exposed to different processes

In this study, different process types were processed on Hardox 400 steel. These processes were carried out with five different samples as heat treatment, cold forging, plasma welding, mig-mag welding and commercial sample. The aim here is to determine the changes in properties such as microstructure, microhardness and conductivity that occur in the structure of hardox 400 steel when exposed to different processes. Then, the samples affected by these changes were processed in WEDM with the box-behnken experimental design. Ra, Kerf, MRR and WWR results were analyzed in Minitab 21 program. In the continuation of the study, using these data, a prediction models were created for Ra, Kerf, MRR and WWR with Deep Learning (DL) and Extreme Learning Machine (ELM). Anaconda program Python 3.9 version was used as a program in the optimization study. In addition, a linear regression models are presented to comparison the results. According to the results the lowest Ra values were obtained in heat-treated, cold forged, master sample, plasma welded and mig-mag welded processes, respectively. The best Ra (surface roughness) value of 1.92 µm was obtained in the heat treated sample and in the experiment with a time off of 250 µs. Model F value in ANOVA analysis for Ra is 86.04. Model for Ra r2 value was obtained as 0.9534. The lowest kerf values were obtained in heat-treated, cold forged, master sample, plasma welded and mig-mag welded processes, respectively. The best kerf value of 200 µ was obtained in the heat treated sample and in the experiment with a time off of 200 µs. Model F value in ANOVA analysis for Kerf is 90.21. Model for Kerf r2 value was obtained as 0.9555. Contrary to Ra and Kerf, it is desirable to have high MRR values. On average, the highest MRR values were obtained in mig-mag welded, plasma welded, cold forged, master sample and heat-treated processes, respectively. The best mrr value of 200 g min−1 was obtained in the mig-mag welded sample and in the experiment with a time off of 300 µs. Model for MRR r2 value was obtained as 0.9563. The lowest WWR values were obtained in heat-treated, cold forged, master sample, plasma welded and mig-mag welded processes, respectively. The best wwr value of 0.098 g was obtained in the heat treated sample and in the experiment with a time off of 200 µs. Model F value in ANOVA analysis for WWR is 92.12. Model for wwr r2 value was obtained as 0.09561. In the analysis made with artificial intelligence systems; The best test MSE value for Ra was obtained as 0.012 in DL and the r squared value 0.9274. The best test MSE value for kerf was obtained as 248.28 in ELM and r squared value 0.8676. The best MSE value for MRR was obtained as 0.000101 in DL and the r squared value 0.9444. The best MSE value for WWR was obtained as 0.000037 in DL and the r squared value 0.9184. As a result, it was concluded that different optimization methods can be applied according to different outputs (Ra, Kerf, MRR, WWR). It also shows that artificial intelligence-based optimization methods give successful estimation results about Ra, Kerf, MRR, WWR values. According to these results, ideal DL and ELM models have been presented for future studies.

A critical review on different aspects of electric discharge machining

EDM is a common manufacturing technique that separates the tool and the workpiece during the sparking process. This prevents the tool and the workpiece from contaminating each other. EDM requires a variety of tool and the components in order to determine the Metal Elimination Rate and the Tool Degradation Rate. The MRR and TWR were significantly altered as a direct result of the utilisation of a variety of dielectric fluids. The procedure parameters of EDM, which include current supplied, the voltage differential, process timely manner and blend off time etc., are the main variables that need to be analysed in order to determine MRR and TWR. This is true regardless of the distinct characteristics dielectric fluids that are being used. Several distinct optimisation strategies, including Taguchi, ANOVA, and TOPSIS, were utilised in order to optimise the processing parameter in such a way that it would result in a high MRR and a low TWR. In order to evaluate and optimise the data using MiniTab, an orthogonal matrix consisting of L9 and L27 elements is utilised. In the current article that is a review, the research studies that were conducted with various types of dielectric fluid, tools, and work pieces, as well as variable processing parameters and variable optimisation techniques, are identified and then described in detail.

Effects of Blended NPS Fertilizer Rates on the Yield Components and the Yield of Bread Wheat Varieties (Triticum aestivum L.)

The use of improper fertilizer type and amount, the cultivation of unimproved, low-yielding varieties and poor soil fertility are among the main obstacles limiting the productivity of wheat in Ethiopia in general and in the study area in particular. A field trial was therefore initiated to evaluate the effects of blended NPS fertilizer rates on the yield components and the yield of bread wheat varieties and to identify economically justifiable amounts of blended NPS fertilizer in the study area. The experiment was set up in RCBD with three replicates in which three bread wheat varieties (Ogolcho, Jalane and Sanate) and five levels of mixed NPS fertilizers (0, 50, 100, 150 and 200 kg ha-1) were assessed in a factorial combination. The results showed that all properties of the bread wheat varieties were significantly (p <0.01) influenced by the main effects of the variety and the NPS fertilizer. The highest (0.43) and the lowest (0.36) harvest index were obtained from 150 kg ha-1 NPS. The interactions of the two main factors only affect the total number of tillers, the number of productive tillers, the aboveground biomass, the grain and straw yield. Similarly, the highest and lowest (11.04 and 1.13) agronomic efficiencies were obtained from the combination of 150 kg NPS ha-1 with the Sanate variety and 50 kg ha-1 with the Jalane variety. The highest profitability (82710 ETB ha-1) and a higher MRR (2305.8%) are obtained from the Sanate variety with an application rate of 150 kg ha-1 NPS. Based on the results of this study, it can be concluded that the application of 150 kg ha-1 NPS and the cultivation of the Sanate variety could be the better choice of the farmers of the study area in order to achieve high yields with higher returns.

Optimization of Surface Roughness and Material Removal Rate in Turning of AISI D3 Steel with Coated Carbide Inserts

The aim of this paper is to optimize the metal removal rate and surface roughness through turning on AISI D3 Steel with coated carbide inserts. As per the current market scenario, for the metal cutting industries the most important challenge in the turning process is to satisfy both requirements quality as well as high productivity in less time in order to remain competitive. Among all the different cutting processes, the turning process is one of the most applied and fundamental metal removal operations in the real manufacturing environment. This work examines the impact of machining factors like speed, depth of cut & feed on roughness and MRR of AISI D3 steel which have a hardness value of 60 HRC with coated carbide inserts. At high speed and feed rate optimum MRR was achieved and opposite to that at low feed and depth of cut optimum surface roughness was obtained. Taguchi L9 (3)3 OA has been applied for experimental design. ANOVA analysis is performed just after DOE to identify the significant factor which influences MRR and surface roughness. Among the three machining factors, depth of cut and speed has more influencing effect on roughness and the feed influences MRR. Effort was made to find optimum solution to minimize the roughness and maximize the MRR by Taguchi and ANOVA technique.

Evaluation of Blended NPS Fertilizer Rates and Inter Row Spacing on Yield Components and Yield of Maize (Zea Mays L.)

Corn is an important cereal crop in Ethiopia due to its use as a source of food security. However, its productivity is limited by insufficient application of the NPS fertilizer and different row spacing. A field trial was carried out to assess the effects of the application of different NPS fertilizer quantities and inter row spacing on the growth, yield components and yield of maize and the cost-benefit analysis of the NPS compound fertilizer application on the yield of maize in the main growing season 2019/2020.The study was arranged in a factorial combination of five levels of NPS fertilizers (0, 50, 100, 150 and 200 kg NPS ha-1) and four inter row spacing (55 cm, 65 cm, 75 cm and 85 cm). in a randomized complete block design with three replications. The consequence showed the main result of the NPS fertilizer had a highly significant (p <0.01) effect on days up to 50% anthesis, days up to 50% silk formation, 90% physiological maturity, leaf area, leaf area index, number of plants at harvest, the number of grains per ear was determined from the main effects of NPS fertilizer of 200 kg NPS ha-1. The interaction effects of NPS and row spacing have highly significant (p <0.01) effects on the number of ears per plant, number of ears per hectare, ear length, agronomic effectiveness and grain yield were obtained when using 150 kg. measured NPS ha-1 at 75 cm row spacing. The highest economic (91,608 Birr ha-1) and a higher MRR (1745%) resulted from the 150 kg NPS ha-1 and 75 cm row spacing. Thus, it should be noted that the application of 150 kg NPS ha-1 with a row spacing of 75 cm was both agronomic and cost-effective for the grain yield of the Melkassa-II in the study area.

Electrostatic Self-Assembled Composite Abrasives for Chemical Mechanical Polishing of A-Plane Sapphire

Sapphire substrates with different orientations have wide applications due to their excellent physical, chemical and optical properties. However, the chemical mechanical polishing of sapphire is challenging due to its chemical inertness, extreme hardness and brittleness. Herein, chemical mechanical polishing of A- and C-plane sapphire was systematically studied using α-Al2O3 and silica abrasives and polishing mechanism was analyzed by X-ray photoemission spectroscopy (XPS) and nanoindentation meter. The high MRR selectivity for C-plane sapphire in α-Al2O3 slurry is the synergy of selective hydration of C-plane and stronger crystal structure of A-plane. The low MRR selectivity for C-plane sapphire in silica slurry can be attributed to the formation of Al2SiO5 on both planes which reduced the impact of strong mechanical effect of α-Al2O3 abrasives. To improve the MRR of A-plane sapphire, a new nanocomposite particle with alumina as the core and silica as the soft shell was prepared by an electrostatic self-assembly method. The new composite abrasives combined the mechanical effect of α-Al2O3 abrasives and chemical effect of silica abrasives and demonstrated substantially higher MRR for A-plane sapphire than pure alumina abrasives, pure silica abrasives and physical mixture of alumina+silica abrasives.

OPTIMASI MATERIAL REMOVAL RATE (MRR) BAJA ST 42 PADA PROSES CNC TURNING DENGAN MENGGUNAKAN METODE TAGUCHI

Abstract High MRR is a goal to be achieved in the workpiece machining process using CNC turning. But the slow process will affect the processing time of the product, and will increase production costs. To overcome this, it is necessary to set appropriate process parameters to produce the most influential contribution to MRR and also to produce optimum parameter values. The purpose of this study was to determine the effect of parameters (cutting speed, spindle speed and depth of cut) on MRR and to determine the correct process parameter settings in order to produce optimal MRR on ST 42 steel. The study was conducted using ST 42 steel and using carbide chisels on CNC turning process. The process parameters that will be varied are spindle speed, feeding motion, and infeed depth. The experimental design used was orthogonal matrix L9(33). The repetition is done twice. Furthermore, the optimization of multi-response characteristics is carried out using the S / N Ratio method. From the research results, it was found that in order to reduce the variance of the response simultaneously, the infeed depth had the largest percentage contribution value, which was 46.642%, the spindle speed had a percentage contribution value of 14.362%, and then the feeding motion with a percentage contribution value of -7.548 And to obtain the optimal MRR of the workpiece, the spindle speed is set at 1500 rpm, the feeding motion is set at 0.5 mm / put, and the infeed depth is set at 1 mm. Keywords: Carbide, CNC Turning, Taguchi, S/N Ratio, MRR

Experimental Investigation on Surface and Machining Characteristics of Micro ED Milling of Ti-6Al-4 V with Different Nano Powder Mixed Dielectrics

Micro ED milling is a micro machining technique for machining of high-quality micro parts on the electrically conductive material. Achieving a good surface finish with higher material removal is difficult in Micro ED (μED) Milling due to the short circuits and arcing attributed to partial removal of debris. In this research work, an attempt has been made to improve the quality of machined surfaces in the milling process without compromising the machining characteristics using nano powder mixed dielectrics such as Silicon carbide (SiC) and Carbon nano tubes (CNT). The milling trails were carried out using Tungsten carbide (WC) electrodes under adopted levels of powder concentration and discharge energy region in order to determine the best condition for achieving maximum material removal and excellent surface finish. Further, the morphology of the machined surface was examined using Scanning Electron Microscope (SEM) and found that ridges, crater size and overlapping of craters were considerably reduced due to addition of nano powders in dielectric resulted in high surface finish. The micro cracks are larger with higher discharge energy for all dielectrics used, whereas it is significantly reduced with nano powder mixed dielectrics as compared to plain dielectric. CNT powder offered high MRR and the minimum EWR as compared to other dielectrics used. Both the CNT and SiC powder mixed dielectrics have marginally improved the surface hardness. Results indicated that the electrical conductivity of dielectric has a significant effect on machining and surface characteristics. The surface texture achieved with CNT mixed dielectric looks better than that of other dielectrics: especially with the higher order of powder concentration of 0.9 g/l. Milling trails were designed using full factorial design for plain and nano powder mixed dielectrics.

Highly efficient smoothing of Inconel 718 via electrochemical-based isotropic etching polishing

For the highly efficient and versatile polishing of metals, isotropic etching polishing (IEP), which is based on the merging of isotropic etching holes, has been developed. In this study, the feasibility and mechanism of isotropic etching polishing of nickel-based superalloy Inconel 718 (IN718) and the polishing characteristics have been studied. The potentiodynamic experiments revealed similar trends of the cathodic, passive, second passivation, and transpassive regions in all the electrolytes, while the corrosion susceptibility of IN718 successively decreased with the increasing H2SO4 concentration in the electrolyte. The etching anisotropy of the IN718 precipitated with different phases can be experimentally transmuted to isotropic etching by modulating the electrolyte concentration and keeping electrolyte temperature equal or above the room temperature. Because of the positive correlation of the etching current with isotropic holes density and diameter, etching at higher currents is promoted for the rapid and proficient polishing. The surface evolution mechanism during IEP has been confirmed. The surface roughness initially increased due to the formation of etching holes, then decreased abruptly owing to the rapid merging of etching holes and finally achieved a smooth surface. The wet grounded surface of IN718 with a roughness of Sa 62.7 nm has been transformed into a mirror-like smooth surface with a roughness of Sa 0.86 nm within 300 s of IEP at optimized conditions and a high MRR of 2.73 mm3/min has been achieved.

Optimization of SiC Abrasive Parameters on Machining of Ti-6Al-4V Alloy in AJM Using Taguchi-Grey Relational Method

In this research, multi response Taguchi-grey relational approach was employed to optimize the machining parameters of Ti-6Al-4V alloy in abrasive water jet process. The main aim of this present investigation was to explicate the role of adding SiC super hard ceramic into the garnet and to find out the optimal input variable, which is influencing the material removal rate and surface finish in the process. The specific input variables such as SiC volume, SiC size and abrasive flow rate were accounted as potential process variables for this present investigation. It is observed that the SiC along with garnet improves the material removal rate. According to the analysis the SiC addition of 0.5 wt.%, SiC size of 80mesh and abrasive flow rate of 2 g/s (A2B1C1) was found to be producing MRR of 48.81 mm3/s and lower surface roughness of 3.72 μm. From study the particle size was the most influential parameter for producing high MRR with low surface roughness. The confirmation study reveals the improvement of 1.91% in MRR and surface roughness on comparing with predicted mean value.

Influence of process parameters on laser beam machining of leather for oil hydraulic system application

Laser Beam Machining (LBM) is an unconventional process where the laser beam is directed to the work piece where the thermal energy is utilized to remove the material. Laser Beam Machining (LBM) is best suited for machining tough to cut material like leather as it provides several advantages like high precision, and no tool wear as there is no contact between work piece and nozzle. Leather seals are used in oil hydraulic systems. The laser beam machining was carried out for leather with different levels of process parameters like Power (P), Transverse Speed (Sp), Standoff Distance (SOD) and Gas Pressure (G.Pr) and its effect on various response parameters such as MRR, Conicity, Overcut and Circularity are studied. From the results obtained, out of two trials conducted on leather the second trial has high MRR, better overcut and circularity because of the fact that second trial has lesser SOD so the intensity is more and beam divergence is less compared to trial one. The most influential parameter for leather is transverse speed because the heat transfer on the workpiece gets changed with respect to time available for the heat to spread.

Sustainable machining: Modelling and optimization using Taguchi, MOORA and DEAR methods

Sustainable machining of metallic parts offers significant economic, environmental and societal benefits to metal cutting industries. Although dry machining technology bring sustainability in machining industries but requires significant attention to get high productivity without affecting the geometrical accuracy and surface finish. The present work proposed a unified framework to model and optimize the process, when applied to sustainability. A CNC machine is used to turn the mild steel parts with the help of carbide inserts (TNMG 160408CQ). Taguchi L27 orthogonal array is used to model the turning process and analyze the factors (cutting speed, depth of cut and feed rate) on material removal rate, MRR, surface roughness, SR and circularity error, CE. Further, attempts are made to optimize the sustainability index taken into account of economic (higher MRR), social (desired lower SR and CE) and environmental (dry machining) aspects. To attain the said goal two popular optimization models (data envelopment analysis ranking, DEAR and multi-objective optimization on the basis of ratio analysis, MOORA) are considered. The said models are compared among themselves and proposed a single optimal condition for the turning process.

Machining performance enhancement of powder mixed electric discharge machining using Green dielectric fluid

Towards the requirement of sustainable development, manufacturing industries are required to follow ISO-14000 standards. Therefore, it is necessary to follow sustainability criteria for manufacturing processes. Vegetable oil-based fluids have proven their potential towards the various industrial applications and establish themselves as a sustainable fluids as compared to hydrocarbon and synthetic-based fluids. In the present study, the authors have evaluated the practical acceptability of newly proposed Schleichera oleosa (Kusum oil) as an alternative of hydrocarbon-based EDM oil. The improvement in machining performance of MWCNT mixed rotary EDMing of EN-31 die steel using Kusum oil as a dielectric is evaluated in terms of MRR and SR. Response surface methodology along with genetic algorithm is used for the mathematical modelling and optimization of MRR and SR both. The optimization result shows that MWCNT mixed rotary EDM using Kusum oil as a dielectric shows approximately 57.14% higher MRR and 54.57% lower SR, respectively, as compared to conventional EDM using EDM oil as a dielectric. Finally, the surface topography images obtained from FESEM analysis also confirm the superiority of Kusum oil over EDM oil.

Optimization of machine machining parameters in EDM of silicon nitride-titanium nitride based on RSM

EDM of silicon nitride–titanium nitride ceramic composites with copper electrode was carried out here. Input factors of outstanding significance like current (I), spark gap voltage (SV), pulse-on duration (T on ) and pulse-off duration (T off ) were selected to calculate listed technological characteristics. The output responses measured were material abrasion loss (MRR) and electrode abrasion rate (EWR). Also, the distinguishing face of the EDM technique is delved by RSM (Box-Benhken method) based on Design of Experiments (DOE) and experimental results are evaluated by Analysis of Variance (ANOVA). Furthermore, L 29 orthogonal array (OA) based on the DOE to carry a row of machining has been followed here. From experimental outcomes, it is apparent that the current is the highly significant parameter among other factors as it alters both material abrasion loss and electrode abrasion rate. On the other part, difference in the pulse-off duration did not affect the responses. The higher material abrasion loss is obtained when current and pulse-on duration is higher and the increased gap voltage and lower current reduces the EWR. The higher MRR is obtained for current – 6 amps, pulse-on duration – 7 µsec, pulse-off duration – 10 µsec and spark gap voltage – 35 V. Reduced EWR is obtained for current – 4 amps, pulse-on duration – 6 µsec, pulse-off duration – 10 µsec and spark gap voltage – 40 V.