Material Pulse on Pulse Wire feed Wire Servo M/c Cutting Kerf MRR

composition time off (mm/min) Tension voltage time speed(c) width(k) (g/min)
(%) (µs) time (N) (V) (min) (mm/min) (mm)
(µs)
0.5% 110 55 1 3 5 9 2.81 0.287 0.0214
0.5% 110 55 1 3 5 9 2.79 0.299 0.0221
0.5% 105 60 1 3 5 10 2.42 0.293 0.0188
0.5% 105 60 1 3 5 10 2.40 0.294 0.0187
1% 110 55 1 3 5 8 2.83 0.299 0.0225
1% 110 55 1 3 5 8 2.85 0.287 0.0217
1% 105 60 1 3 5 10 2.39 0.320 0.0203
1% 105 60 1 3 5 9 2.42 0.312 0.0200
2% 110 60 1 3 5 8 2.78 0.290 0.0214
2% 110 60 1 3 5 8 2.80 0.295 0.0219
2% 105 55 1 3 5 10 2.45 0.315 0.0205
2% 105 55 1 3 5 10 2.45 0.315 0.0205
5% 110 60 1 3 5 7 2.86 0.284 0.0216
5% 110 60 1 3 5 7 2.89 0.282 0.0216
5% 105 55 1 3 5 9 2.70 0.297 0.0213
5% 105 55 1 3 5 9 2.68 0.305 0.0217

Density(d) = 0.0028g/mm3

Thickness(t) = 9.5mm

MRR = d*k*t*c
Optimization Techniques

3.1.GREY BASED TAGUCHI METHOD:-Genichi Taguchi, a Japanese scientist,

developed a technique based on OA of experiments. This technique has been
widely used in different fields of engineering to optimize the process parameters.
The integration of DOE with parametric optimization of process can be achieved in
the Taguchi method. An OA provides a set of well-balanced experiments, and
Taguchi’s signal-to-noise. (S/N) ratios, which are logarithmic functions of the
desired output, serve as objective functions for optimization. It helps to learn the
whole parameter space with a small number (minimum experimental runs) of
experiments. OA and S/N ratios are used to study the effects of control factors and
noise factors and to determine the best quality characteristics for particular
applications. The optimal process parameters obtained from the Taguchi method
are insensitive to the variation of environmental conditions and other noise factors.
However, originally, Taguchi method was designed to optimize single performance
characteristics. Optimization of multiple performance characteristics is not straight
forward and much more complicated than that of single-performance
characteristics. To solve the multiple performance characteristics problems, the
Taguchi method is coupled with grey relational analysis. Grey relational analysis
was first proposed by Deng in 1982 to fulfill the crucial mathematical criteria for
dealing with poor, incomplete, and uncertain system. This grey-based Taguchi
technique has been widely used indifferent fields of engineering to solve multi-
response optimization problems.
The procedure of the grey-based Taguchi method is shown in Figure 1.In
Figure 1, steps 1, 2 and 7 are general procedures of the Taguchi method.
Fig 3. Procedure of the Taguchi method.
4.4. Response variables
4.4.1. Surface roughness
Surface roughness values of finished work pieces were measured by Mitutoyo
Surface
Roughness Tester SJ – 201 by. It is an instrument that works by gently dragging
a mechanical stylus across a Surface. Surface Roughness Tester acquires data by
moving the sample beneath the diamond tipped stylus. Vertical movements of the
stylus are sensed by an LVDT, digitalized, and stored in the instruments memory.
Surface Roughness Standard ISO was used for measurement. The temperature of
environment was 32 ± 1
oC. In this present study we have taken Ra for measuring
Surface Roughness.
4.4.2. Kerf width
It is measured in millimeters (mm). It is the measure of the amount of the material
that is wasted during machining and determines the dimensional accuracy of the
finishing part. For present experiments kerf width has been measured using Nikon
profile projector model 6C.
4.4.3. Method adopted in optimization
Genetic algorithm
Genetic algorithm (GA) is a search and optimization method which works by
mimicking the evolutionary principles and chromosomal processing in
naturalgenetics.GA begins its search with a random set of solutions usually coded
in binary
strings. Every solution is assigned a fitness which is directly related to the
objective function of the search and optimization problem. The genetic algorithm
is
an evolutionary algorithm that uses genetic operators to obtain optimal solutions
without any assumptions about the search space. Genetic algorithms need design
space to be converted into genetic space. So, Genetic algorithms work with a
coding of variables. The advantage of working with a coding of variable space is
that
coding discretizes the search space even though the function may be continuous.
Each chromosome can represent a feasible solution containing a sequence/string of
binary or real numbers known as genes.
5. Results and discussion In the present study, GA is used as an optimization
technique for solving a bound– constrained optimization problem. The regression
models developed by RSM have been used as objective function and the upper and
lower bounds of parameters are identified by conducting experiments. The problem
can be formulated as given below. The main aim is to minimize the surface
roughness value. The analysis of variance is the statistical treatment most
commonly applied to the results of the experiment to determine the percent
contribution of each factors. Study of ANOVA table for a given analysis helps to
determine which of the factors need control and which do not. Once the optimum
condition is determined, it is usually good practice to run a confirmation
experiment. In case of fractional factorial only some of the tests of full factorial are
conducted.The analysis of the partial experiment must include an analysis of
confidence that can be placed in the results. So analysis of variance is used to
provide a measure of confidence

Physical Properties
The physical properties of aluminum 7075 alloy are tabulated below.

Properties Metric Imperial

Density 0.0028 g/mm3 0.101 lb/in3
Melting point 483°C 900°F

Table 7 Specifications of wire cut EDM

Dielectric Distilled water

Maximum workpiece size 400 x 500 x 200 mm

Maximum travel 250 x 350 x 200mm

Manufacture Electronica

Experimental Details

• As per the taguchi quality design model L4 orthogonal array table was arbitrarily chosen

to study optimization process. The experimental design has 2 level and 3 factors.

• The process considerations have been optimized by Grey based Taguchi method.

• Experiments have been performed on ECOCUT.

• The dimension of cutting has to measure by using SEM image.

• The experimental design has been done in L9 orthogonal array for modeling of micro

wire EDM process.

Three response parameter were chosen for measured.

• Voltage

• Current.

• Ton