A Study On Optimization Of Process Parameters In Machining Of Bronze .
International Journal of Scientific Research in Science and TechnologyPrint ISSN: 2395-60116011 Online ISSN: 2395-602X2(www.ijsrst.com)doi :https://doi.org/10.32628/IJSRST218562A Study on Optimization of Process Parameters in Machining ofBronze using WireWire-EDM1Gajanan Kamble*1, Dr. N. Lakshamanaswamy2, Gangadhara H S 3, Sharon Markus 4, N. Rajath5PG Scholar, Department of Mechanical Engineering, University Visvesvaraya College of Engineering, Bangalore,India2Professor and Former Chairman , Department of Mechanical Engineering, University Visvesvaraya College ofEngineering, Bangalore, India3PG Scholar, Department of Mechanical Engineering, University Visvesvaraya College of EEngineering, Bangalore,India4PG Scholar, Department of Mechanical Engineering, East West Institute of technology, Bangalore, India5PG Scholar, Department of Mechanical Engineering, B.M.S College of Engineering, Bangalore, IndiaABSTRACTArticle InfoVolume8, Issue 5Page Number:484-493Publication IssueSeptember-October-2021Article HistoryAccepted :16Oct2021Published :30Oct2021I.Wire cut electrical discharge machining (WEDM) is a hybrid manufacturingtechnology which enables machining of all engiengineeringneering materials. This researcharticle deals with investigation on Optimization of the Process Parameters of thewire cut EDM of Bronze material of dimension (80*80*40) in mm. Materialremoval rate, Surface roughness and Kerf width were studied against tthe processparameters such as Pulse on time(TON), Pulse off time (TOFF) and Current(IP).The machining parameters for wire EDM were optimized for achieving thecombined objectives. As there are three input parameters 27 experiments is carriedout and full factorial is used. Optimized parameters were found using (ANOVA)and the error percentage can be validated and parameter contribution for theMaterial Removal RRateate (MRR) and Surface roughness were found.Keywords: Wire EDM (Electrical Discharge Machining)achining), Bronze, ANOVA(Analysis of Variance)INTRODUCTIONMechanical Industries aims at quality and time withrespect to efficiency of the product, demand,competence and global acceptance as well. It alsoconveys the necessity in using complicated parts andprecise components which are having good dimensionaltolerances with special shapes. The demand and needfor temperature resistant, hard, tough, wear, corrosionand abrasive resistant materials are increasing day byday. These increasing trends needs have enforced on theusage of advanced and well-equippedequipped technologies toconvert the raw materials into finished products withlow cost and time required for the operations such astooling.The traditional machining processes, in spite ofrecent advancements, fails to machine difficult tomachine components in high strength, high temperature,hard and die steels as well. Considering these scenariosinto account, a number of an conventional machiningprocesses have been discovered and developed.Unconventional machining methods such as Ultrasonicmachining, electrochemical machining, electricaldischarging machine (EDM) can be applied inmachining of components which are difficult tomachine. The non-traditionaltraditional machining methodsexhibit few unique advantages overovconventionalCopyright: the author(s), publisher and licensee Technoscience Academy. This is an openopen-accessaccess article distributed under theterms of the Creativeve Commons Attribution NonNon-CommercialCommercial License, which permits unrestricted non-commercialnonuse,distribution, and reproduction in any medium, provided the original work is properly cited484
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-493techniques which are not restricted by any mechanicalproperties such as toughness, brittleness and hardness. Itensures good surface finish on any intricate componentsby excellent control over physical parameters. Since theconventional methods are not suitable for machininghard materials, non-traditional machines are used whichare feasible, economical too. There are somecharacteristics listed below which provides thelimitations of conventional techniques.Removal of the metal in the form of chips is a difficultprocedure.II. METHODS AND MATERIALMaterial preparationThe work piece material used for the experimentalanalysis is bronze with dimensions of80mm*80mm*40mm. The work piece is initiallysurface cleaned before conducting the experiments.The molybdenum wire with diameter 0.18mm isused as electrode. The machining accuracy is0.01mm. DK 7732 CONCORD wire EDM Machineis used for the experimentation.1. Chips are usually unwanted in the process ofmetal removal.2. Chips removal and the disposal of the chips aretedious, involves the wastage of energy andmoney.3. Since the presence of larger cutting forces, it isdifficult to hold the work piece properly. Properholding of the work piece also avoids distortion.4. Due to the excess amount of heat is generated atthe interface of tool and work piece; there willbe some undesirable effects which diminishesthe properties.Developing these non-traditional methods encouragesthe machining of complex shaped dies and moulds inhard and high temperature resistant alloys for exampletitanium alloys, carbides, heat resistant steels etc. Thesenon-traditional machined components have greaterapplications in the fields of nuclear engineering andaerospace industriesNew advanced/ technological processes are divided intodifferent categories.(a) Type of energy (Shaping of materials)–thermal,Mechanical, Electro thermal and Electro chemical;(b)The process involves some basic mechanisms suchas ionic dissolution, erosion and vaporization;(c) Energy sources required in removal of material–high current density, hydrostatic pressure, ionizedmaterial, high voltage.(d)Transferring of energies in a particular medium –electrolyte, Electron, hot gases and high velocityparticles.Figure 1.Bronze Material used for experimentationPreliminary experimentation:Three parameters were chosen, namely Pulse On, PulseOff. and Current. These parameters were variedsimultaneously so as to obtain the minima and maximaof the chosen set of parameters. The response variableconsidered in this regard was material removal rate andwire strength. As the material removal rate wasincreased, probability of snipping of wire increased.The maximum MRR was achieved keeping in mind thewire life.Sl No.ParameterMaterialRemovalRateMaximumMinimumPulse on PulseCurrent((μs)Off(μs) A)351052583Equipment used for ExperimentationDK 7732 CONCORD Wire EDM Machine is used forthe experimentation; molybdenum wire is used for theexperimentation. Once the wire is wound on the wiredrum, that particular amount of. Wire will be used forall the experiments and it can be replaced once thematerial is changed. Work material will be clampedtightly on the work table so as to avoid any relativemotion between work piece and the wire. Dielectricflow is constant during the experiment.International Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5485
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-493Experimental Design (Input parameters)Sl. Processno parameters1 Pulseontime(Ton)2 Pulseofftime(Toff)3 345The experimental design was according to Fullfactorial. Table shows the process parameters with theirlevel consider for this experimentation.1.2.3.4.5.6.The Bronze material is clamped tightly sothat there is no movement of work piecematerial during machining.The Molybdenum wire is wound on thewire drum which is brought near thematerial during machining.The table movement should be adjusted sothat the wire comes in contact with thework piece.The values of input parameters are fed tocomputer which is in connected to the WireCut EDM machine.The electric discharge is produced and dielectricfluid is sprayed on the bronze material.The machining of the bronze material takes placeand output parameters can be calculated.Figure.2 Wire Electrical Discharge MachineFigure3 Surface Roughness testerThe measurement of Surface Roughness was done usingTaylore Hobbson Surtronic device. The reason for usingthis device is that they are tough, fast and reliabletesters. The device used is user friendly. Surtronic seriesstand and primer the integrated roughness measurementstation can be obtained. Roughness measurements canbe easily done and on multiple parts and results can bestored internally or in a standard USB device.Durable roughness testers are used for shop floor,industrial and inspection room applications.III. METHODOLOGYAnalysis of Variance (ANOVA)ANOVA is a standard statistical technique which isused to interpret the experimental results. Thepercentage contribution of various process parametersto the selected performance characteristic can also beestimated by ANOVA technique. Thus, informationabout how significant the effect of each controlledparameter is on the quality characteristic of interest canbe obtained. ANOVA for raw data has been done toidentify the important parameters and to quantify theireffect on the performance characteristic. The ANOVAbased on the raw data helps to identify the factorswhich affect average response rather than reducingvariation.ANOVA is used in testing and significance of all themain factors and interactions and mean square valuesand experimental errors at specific confidence level.Study of ANOVA table helps to determine the factorswhich needs controls and which factors do not needcontrol. The confirmation experiment is done todetermine the optimum conditions. The analysis ofpartial experiment consists of analysis of.Confidencewhich can be shown in the results.International Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5486
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-493IV. RESULTS AND DISCUSSIONInputandoutput parametervaluesExpt.No. PulseON PulseOFF CurrentWbWaWb-Wa 611.3210.04021.030.00190204.6010.0210.010.01EFFECT OF PROCESS PARAMETERS ON MRR1. Effect ofPulseONTimeon MRRThe figure 4. shows the relationship between Pulse onTime and MRR. This may be due to reason that withhigh pulse on time, more material gets melted at thetool work piece interface, which require properflushing time but as the value of pulse off time is tooshort, so there is not enough time for the flushing toclear the debris from the inter-electrode gap betweenthe tool and work piece, so arcing take place whichresult in decreasing the MRR.2. Effect of Pulse OFF Time on MRRThere is a decrease in the MRR with an increase in thePulse Off Time. MRR and Pulse Off Time are inverselyrelated. The MRR decreases with lesser amplitude of.Variations from 8to10 as shown in figure 4. This isbecause number of .discharges within the desiredperiod of time becomes smaller due to the timebetween two pulses which leads to lower cutting speed.International Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5487
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-493Also, there may be due to reduction in melting rate andspark ignition ratio in the plasma channel which causeslower MRR.3. Effect of Peak Current on MRRFigure 4 shows the significant increase in MRR withincrease in peak current. This is because of the fact thatwith increase in the value of peak current, theenergy/discharges get enhances which leads to wardsincrease in the cutting speed and material removal rate.Regression EquationMRR 0.001185-0.000011Pulse on -0.000077Pulse off 0.000419 CurrentSurface RoughnessFigure4 Main Effects plot for Material removal rateInternational Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5489
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-493The figure4.4 shows the Main effects plots forSurface Roughness.1. As the pulse on time increases from 25 to 35, themean of Surface Roughness increases gradually. Theincrease in surface roughness was observed withincreased pulse on time. This is because of increasedpulse on time which produces larger discharge energybetween electrode and the work piece. It ceases tomelt more amounts of. Material which helps to createa larger and deeper crater.2. As the pulse off time increases from 8 to10, themean of roughness remains constant from 8 to 9 andincreases from 9 to 10. As the increase in pulse offtime, there were no changes in the surface roughnesses during machining of bronze material. This isdue to the time between the pulse width which is inconsequentially increased and which is not muchaffecting the ratio of pulse energy in the plasmachannel between the electrode and work piecesurface.3. As the current increases from 3 to5, the mean ofsurface roughness increases from 3 to4 but decreasesgradually from 4 to5. The mean of surface roughnessincreases from 3 to4 due to the presence of largerdischarge energy as the current is increased and form4 to 5 the melting of material and large and deepercrater decreases the surface roughness.Regression Equation 1.95 0.0533 Pulse on 0.0167Pulse off 0.1333 CurrentThe statistical and experimental values are shown inthe table. The experimental values formetal removalrate and surface roughness are shown in the table. Thestatistical values are obtained by substituting thevalues of input parameters in the regression equation.Regression EquationMRR 0.001185-0.000011 Pulse on- 0.000077 Pulseoff 0.000419 CurrentRegression EquationSur Rou 1.95 0.0533 Pulse on 0.0167 Pulse off 0.1333 International Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5490
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-493The graph 4.5 shows the interaction plots for KerfwidthThe graph 4.6 shows the main effect plots for Kerfwidth1. As the pulse on time increases from 25 to 35, the Kerfwidth also increases. This because unevenly distributionof sparks and the discharge energy also decreases so thepulse on time increases.2.As the pulse off time increases from 8to10, the Kerfwidth decreases gradually. The reason for decrease inKerf width is with the decrease of discharge duration,the overcut during discharge also increases as thedischarge energy per pulse increases.3. As the current increases from 3 to 5, the Kerf widthdecreases gradually. The main reason behind this is thathigher the peak current, higher will be the sparkenergy. This high spark energy produces larger amountof debris. The debris sticks on the work piece trap andmay cause unwanted spark. The unwanted sparks resultin tool material erosion, which results in less materialremoval, as the significant amount of spark energy isused in sparking. With debris, leading to less Kerfwidth.EDS (Energy dispersive X-ray spectrometry)EDS makes use of the X-rays emitted when a beam ofelectrons hits the sample. This provides the informationregarding the chemical composition present in thesample. In this project chemical composition is checkedfor Bronze Material. The major principal elementspresent in the bronze material are copper with 69.37%.The other elements like zinc, lead, carbon and tin arepresent in the small percentages.The graph shows the higher peaks of copper whichmeans copper is present in higher percentage which isindicated in the table as 69.37%. The other elementslike Zinc(3.54),Tin(1.82), lead (14.4) and carbon(10.88) are present in small percentages which isindicated by small peaks in the graph.International Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5491
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) :484-4933.The two significant factors which affects surfaceroughness is Pulse ON time and Current.4.The Pulse OFF time has negligible influence onsurface roughness.5. The Material removal rate is found to be maximumat Pulse ON Time-30, Pulse OFF Time10, Current-5.6. The surface roughness was found be minimum atPulse ON Time-25, Pulse OFF Time-9, Current-3.Figure 4.7 Selected area of Bronze material7.EDS (Energy dispersive X-ray spectrometry) analysiswas done on the Bronze sample.8. Kerf width increases with increase in Pulse ONtime, Pulse OFF and current decreases withincrease in Kerf width values.VI. REFERENCES[1].Figure 4.8 Composition of Bronze materialV. CONCLUSIONExperimental investigation on wire electricaldischarge machining of Bronze has been done usingMolybdenum wire of 0.18mm. The performanceparameters included pulse on time(Ton), Pulse offtime (Toff), Current(Ip). Experiments were conductedaccording to L27 Orthogonal Array Design. Theoptimum parameters value combination was foundwhich would yield minimum Surface Roughness (SR)and Maximum Material Removal Rate(MRR).[2].[3].[4].The following conclusions are made.1.The main significant factor which affects theMaterial removal rate is Current.[5].2.Pulse ON time and Pulse OFF time has leastsignificant effect on material removal rate.Atul Kumar and Dr. D. K. Singh, 2012.“Performance Analysis of Wire ElectricDischarge Machining (W-EDM).” InternationalJournal of Engineering Research & Technology(IJERT) Vol. 1 Issue 4, June – 2012, ISSN: 22780181.Pujari Srinivasa Rao, Koona Ramji, BeelaSatyanarayana. “Effect of WEDM Conditions onSurface Roughness: A Parametric OptimizationUsing Taguchi Method.” IJAEST, Volume No. 6,Issue No. 1, pp. 041 – 048.Saurav Datta, Siba Sankar ization of Wire EDM Process UsingResponse Surface Methodology 111 Coupledwith Grey- Taguchi Technique.” InternationalJournal of Engineering, Science and Technology.Vol. 2, No. 5, 2010, pp. 162-183.Nihat Tosun, Can Cogun and Gul Tosun, 2004.“A Study on Kerf and Material Removal Rate inWire Electrical Discharge Machining Based onTaguchi Method.” Journal of MaterialsProcessing Technology 152 (2004) 316-322.Mustafa I lhanGokler, Alp MithatOzano zgu,2000. “Experimental Investigation of Effects ofCutting Parameters on Surface Roughness in TheInternational Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5492
Gajanan Kamble et al Int J Sci Res Sci & Technol. September-October-2021, 8 (5) EDM Process.” International Journal ofMachine Tools & Manufacture 40 (2000) 1831–1848.Chiang, K.T., Chang, F.P, “Optimization of theWEDM process of particle reinforced materialwith multiple performance characteristics usinggrey relational analysis”, Journal of MaterialsProcessing Technology, 180, 96-101. ation of Process Parameter of WireElectrical Discharge Machine by ional Journal of Emerging Technologyand Advanced Engineering, volume 3, issue 4,April (2013)Kamal Jangra, Sandeep Grover and AmanAggarwal “Simultaneous Optimization ofMaterial Removal Rate and Surface Roughnessfor WEDM of WC-Co Composite Using GreyRelational Analysis Along with Taguchi Method”International Journal of Industrial EngineeringComputations 2 (2011) 479–490.Ahmet Hasçalýk and UlasÇaydas “Experimentalstudy of wire electrical discharge machining ofAISI D5 tool steel” Journal of MaterialsProcessing Technology 148 (2004) 362–367.Brajesh Kumar Lodhi, Sanjay Agarwal“Optimization of machining parameters inWEDM of AISI D3 Steel using TaguchiTechnique’’ 6th CIRP International Conferenceon High Performance Cutting, HPC2014 ProcediaCIRP 14 (2014) 194 – 199.G.Selvakumar, G.Sornalatha, S.Sarkar, S.Mitra“Experimental investigation and multi- objectiveoptimization of wire electrical dischargemachining (WEDM) of 5083 aluminum alloy”Trans. Nonferrous Met. Soc. China 24(2014)373 379A book of Modern Machining Processes“Thermal Removal Processes” By P.C Pandey&H. S. ShanProduction Technology by P.C Sharma, Pg. 565572.A book of Description and Development ofElectricalDischargeMachining(EDM).Available on www.sme.orgCite this article as :Gajanan Kamble, Dr. N. Lakshamanaswamy,Gangadhara H S, Sharon Markus, N. Rajath, "A Studyon Optimization of Process Parameters in Machining ofBronze using Wire-EDM", International Journal ofScientific Research in Science and Technology(IJSRST), Online ISSN : 2395-602X, Print ISSN :2395-6011, Volume 8 Issue 5, pp. 484-493, SeptemberOctober2021.Availableatdoi: https://doi.org/10.32628/IJSRST218562Journal URL : https://ijsrst.com/IJSRST218562International Journal of Scientific Research in Science and Technology (www.ijsrst.com) Volume 8 Issue 5493
Wire cut electrical discharge machining (WEDM) is a hybrid manufacturing technology which enables machining of all engineering materials. This research article deals with investigation on Optimization of the Process Parameters of the wire cut EDM of Bronze material of dimension (80*80*40) in mm. Material removal rate, Surface roughness and Kerf .
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