OPTIMIZATION OF PARAMETERS OF WIRE EDM

MACHINE USING NIMONIC 80A

A PROJECT REPORT
Submitted by

KHUSHAL BHANDERI [Reg No: 1021310531]

ABHINAV NAIDU [Reg No: 1021310530]
MANISH KUMAR [Reg No: 1021310498]
Under the guidance of

Mr. S. SENKATHIR, M.TECH.

(Assistant Professor, School of Mechanical Engineering)

in partial fulfilment for the award of the degree

of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
Of

FACULTY OF ENGINEERING & TECHNOLOGY

S.R.M. Nagar, Kattankulathur, Kancheepuram District

MAY 2017

1
 SRM UNIVERSITY
(Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this project report titled OPTIMIZATION OF PARAMETERS OF

WIRE EDM MACHINE USING NIMONIC 80A is the bonafide work of

KHUSHAL BHANDERI, ABHINAV NAIDU, MANISH KUMAR, who have

carried out the project work under my supervision. Certified further, that to the best of

my knowledge the work reported herein does not form any other project report or

dissertation on the basis of which a degree or award was conferred on an earlier

occasion on this or any other candidate.

SIGNATURE SIGNATURE

MR. S. SENKATHIR (M. TECH) Dr. S. PRABHU

GUIDE, Assistant Professor (O.G) HEAD OF THE DEPARTMENT
Mechanical Engineering Mechanical Engineering

Signature of the Internal Examiner Signature of the External Examiner

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 ABSTRACT

Wire electrical discharge machining (WEDM) allows us to manufacture

hard materials, mainly for the aerospace and medical industries. Using

Wire EDM machine we can cut very hard materials which are electro

conductive. Wire cut EDM machine provides us the good surface quality.

In this study, we are going to use such a hard material which is to not easy

to cut with using traditional method. Nimonic 80A is one of the materials

that are developed to be hard, strong and temperature resistant. The

present work describes the development of mathematical models for

correlating the inter-relationships of various Wire EDM machining

parameters of Nimonic 80A material such as: Gap voltage, duty factor and

Feed rate on the response factors such as metal removal rate, Wire wear

ratio and surface roughness. This experiment is done on the basis of the

response surface methodology (RSM) and Grey Relational analysis.

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 ACKNOWLEDGEMENT

It brings us immense pleasure for an opportunity to have Major Project

Thesis at SRM University, Kattankulathur. We would like to thank our
Professor D. Kingsly Jeba Singh, Dean, School of Mechanical
Engineering, Dr. S. Prabhu, Head of the Department, Mechanical
Engineering, and project guide Mr. S. Senkathir, Assistant Professor,
Department of Mechanical Engineering for their valuable guidance
throughout our project. We would also like to thank SRM University
where we have undergone our project for the help extended to us through
the course of the project. We would also like to thank Mr. Sakthivel and
Mr. Mohanmalan from SRM University for their valuable support in
Machining and measurement control.

There is always a sense of gratitude which one expresses to others for their
helpful and needy services, which they render during all phases of life. We
would like to do the same as we really wish to express our gratitude
towards all those who have been helpful to us during different stages of
Major Project and encouraged us with their ideas and views, which were
guiding and motivating factors in completion of mighty and tedious tasks
of project report writing to be a success.

In presenting this Report we would like to convey our deep and profound
gratitude towards all professors & technicians at SRM University for their
co-operation and guidance.

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 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE

ABSTRACT iii
LIST OF FIGURES vii
LIST OF TABLES ix
LIST OF SYMBOLS x

1. INTRODUCTION 1
1.1 EDM process 1
1.2 Classification of EDM 2
1.3 Wire electric discharge machining 3
1.3.1 Wire EDM process 3
1.4 Features of wire EDM process 4
1.4.1 Advantages of Wire EDM machine 5
1.4.2 Disadvantages of Wire EDM machine 6
1.4.3 Applications 6
1.5 Selection of material 8
2. LITERATURE REVIEW 9
2.1 Introduction 9
2.2 Literature survey 9
3. DESIGN OF EXPERIMENT 15

3.1 Wire EDM process parameters 15

3.2 Process parameters 16
3.2.1 Input parameters 16
3.2.2 Response Variables 18
3.3 Generation of design of experiments 19
3.3.1 Introduction 19
3.3.2 Methods of DOE 19
3.3.3 Key terms in DOE 21
3.4 Input parameters 21
3.5 Factors with levels 21
3.6 Fixed values 22

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4. EXPERIMENTAL WORK AND
MEASUREMENT 23
4.1 Introduction 23
4.2 Machining characteristics 25
4.2.1 Surface roughness 25
4.2.2 Material Removal Rate 26
4.2.3 Wire Wear Rate 28
4.2.4 Final data with calculation 28
5. OPTIMIZATION WITH
RESPONSE SURFACE METHOD 29
5.1 ANOVA analysis 29
5.1.1 Introduction 29
5.1.2 ANOVA notations 29
5.1.3 ANOVA for Material removal rate 30
5.1.4 ANOVA for Wire wear rate 32
5.1.5 ANOVA for Surface roughness 34
5.2 Contour plots 36
5.2.1 contour plots for MRR 36
5.2.2 contour plots for WWR 38
5.2.3 contour plots for surface roughness 40
5.3 Result optimizer 42
6. GREY RELATIONAL MULTI
RESPONSE OPTIMIZATION 44
6.1 Introduction 44
6.2 SN ratio formulation 44
6.3 Grey Relational approach 45
6.3.1 Calculation for Grey relational
Coefficient. 46
6.3.2 Final grey average coefficient and
ranking 49
6.4 Confirmation test 50
7. CONCLUSION 51
8. FUTURE SCOPE 52
REFERENCES 53
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 LIST OF FIGURES

FIGURE.NO TITLE PAGE NO

1.1 Classification of Non-Traditional processes 1

1.2 Classification of EDM 2
1.3 WEDM schematic 4
1.4 Various shapes cut with wire cut EDM 6
1.5 Chemical composition 8
1.6 Specimen before machining 8
3.1 Ishikawa Cause and Effect Diagram for
WEDM Process 15
3.2 Shows peak current, pulse-off time and on 16
4.1 Ezeecut wire EDM machine 23
4.2 Fixing the component for machining 25
4.3 Specification of Surfcom 1400g 26
4.4 Testing the surface roughness of specimen 26
4.5 Machined work piece at the machining site 27
5.1 Normality plot of MRR 32
5.2 Normality plot for WWR 33
5.3 Normality plot for surface roughness 35
5.4 Contour plot MRR vs Gap voltage, duty factor 36
5.5 Contour plot MRR vs feed rate, Gap voltage 36
5.6 Contour plot MRR vs feed rate, Duty factor 37
5.7 Contour plot of WWR vs feed rate, Gap voltage 38
5.8 Contour plot of WWR vs feed rate, Duty factor 38
5.9 Contour plot of WWR vs Gap voltage, Duty factor 39
5.10 Contour plot of surface roughness vs Gap voltage,
Duty factor 40
5.11 Contour plot of surface roughness vs feed rate,
Duty factor 40

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FIGURE.NO TITLE PAGE NO

5.12 Contour plot of surface roughness vs gap voltage,

Duty factor 41
5.13 Response optimizer 42
5.14 Optimized response 43

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 LIST OF TABLES

TABLE NO TITLE PAGE NO

1.1 Chemical composition of Nimonic 80A 7

3.1 Factors with their levels 21
3.2 Fixed Variables 22
3.3 Data sheet 22
4.1 Machine specification 24
4.2 Final data with calculation 28
5.1 Factors with parameters 30
5.2 ANOVA table for MRR 31
5.3 ANOVA table for WWR 32
5.4 ANOVA table for surface roughness 36
6.1 Grey relational coefficients of WWR 46
6.2 Grey relational coefficient for Surface roughness 47
6.3 Grey relational coefficients for MRR 48
6.4 Ranks after optimization 49
6.5 Confirmation experiment 50

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 LIST OF SYMBOLS, ABBREVATIONS AND
NOTATIONS

SYMBOL SIGNIFICANCE
MRR Material removal rate
WWR Wire wear rate
SR Surface roughness
EDM Electric discharge machining
WEDM Wire cut Electric discharge machining
Ton Pulse on time
Toff Pulse off time
Gv Gap voltage
Fp Flushing pressure
Wf Wire feed rate
Wt Wire tension
C.F. Correction factor
F Variance ratio
Yij Response values.
n Number of replicants
Xij Normalized response
GCij Grey relational coefficient
Gi Grey relational grade

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 CHAPTER 1
INTRODUCTION

1.1 MACHINING PROCESS

Machining removes certain parts of the work pieces to change them to final parts.
Machining nowadays has been classified in two types: (1) Traditional Machining; (2)
Non-traditional Machining. Traditional Machining, also known conventional
machining requires the presence of a tool that is harder than the work piece to be
machined. This tool should be penetrated in the work piece to a certain depth.
Moreover, a relative motion between the tool and work piece is responsible for forming
or generating the required shape. The absence of any of these elements in any
machining process such as the absence of tool-work piece contact or relative motion,
makes the process a non-traditional or non-conventional one. Non-conventional
machining processes are well established in modern manufacturing industries as they
are capable of machining hard materials. Nonconventional machining processes are
classified according to the machining action which helps in material removal from the
work piece. The material removal mechanism, machining system components, process
variables, technological characteristics, and industrial applications are different for all
these processes.

Figure: 1.1 Classification of Non-Traditional processes

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1.2 CLASSIFICATION OF EDM
There are many EDM processes such as Wire Electrical Discharge Machining,
Electrical Discharge Milling, Electrical Discharge Grinding (EDG), Electrical
Discharge Dressing (EDD), Ultrasonic Aided EDM (UEDM), Abrasive Electrical
Discharge Grinding (AEDG), Micro Electrical Discharge Machining (MEDM), Micro
Wire EDM (MWEDM), Mole EDM, and Double Rotating Electrodes EDM. Pandey
and Shan classified EDM processes into three main categories as shown in Fig. 1.2.

Figure: 1.2 Classification of EDM

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1.3 WIRE ELECTRIC DISCHARGE MACHINING (WEDM)

Wire EDM is considered as a unique adoption of the conventional EDM process which
comprises of a main worktable, wire drive mechanism, a CNC controller, working fluid
tank and attachments. The work piece is placed on the fixture table and fixed securely
by clamps and bolts. The table moves along X and Y-axis and it is driven by the DC
servo motors. Wire electrode usually made of thin copper, brass, molybdenum or
tungsten of diameter 0.05-0.30 mm, which transforms electrical energy to thermal
energy, is used for cutting materials. The wire is stored and wound on a wire drum
which can rotate at1500 rpm. The wire is continuously fed from wire drum which
moves though the work piece and is supported under tension between a pair of wire
guides located at the opposite sides of the work piece. During the WEDM process, the
material is eroded ahead of the wire and there is no direct contact between the work
piece and the wire, eliminating the mechanical stresses during machining. Also, the
work piece and the wire electrode (tool) are separated by a thin film of dielectric fluid
that is continuously fed to the machining zone to flush away the eroded particles. The
movement of table is controlled numerically to achieve the desired three-dimensional
shape and accuracy of the workpiece.

1.3.1 WIRE EDM PROCESS

Wire EDM is a process which erodes and removes material by using the channel of
plasma generated by electric sparks between two conductive materials (i.e. electrode
and the work piece), this channel of plasma converted into thermal energy at a
temperature range of 8000 to 12000 C at a pulsating direct current supply of 20000 to
30000 Hz. The electrode and work piece are separated by a small gap being immersed
in dielectric fluid, an electric spark is produced in between this small gap and the work
piece material is eroded, as the pulsating current is turned off, the plasma breaks down
which leads to sudden reduction in the temperature and the eroded material is flushed
away with the help of dielectric fluid in the form of microscopic debris. With each
electric spark discharge a small crater is formed on both the work piece and the
electrode which is a prime decider in the final surface quality. The taper can range from
15 for a 100 mm thick to30 for a 400-mm thick work piece can be obtained on the
cut surface material. A WEDM schematic is shown in Fig. 1.3.

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 Figure: 1.3 Wire EDM schematic diagram

Deionized water is used as the dielectric as it is the purest form of water and it acts as
an insulator. Normal tap water contains minerals which may be too conductive for Wire
EDM, in order to control the water conductivity; water is deionized by passing it
through a resin tank which eliminates the conductive elements of water. This deionized
water is circulated with the h e l p of a pump. As the machining operation is performed,
conductivity of water rises and it is again re-circulated through the resin tank. The
purpose of deionised water is to stabilise the spark erosion path and to act as the
dielectric medium which is forced into the cutting gap to flush out the eroded metal.
There is virtually no cutting force on the part of the machine because the wire electrode
and work piece never make contact. WEDM process is usually used in conjunction
with CNC and will only work when a part is to be cut completely through. The melting
temperature of the parts to be machined is an important parameter for this process
rather than strength or hardness. The surface quality and material removal rate (MRR)
of the machined surface by wire EDM will depend on different machining parameters
such as applied peak current, and wire materials. WEDM process is commonly
conducted on submerged condition in a tank fully filled with dielectric fluid;
nevertheless, it also can be conducted in dry condition. This method is used due to
temperature stabilization and efficient flushing in cases where the work piece has
varying thickness. i t is the most versatile electrical machining process where erosion
is caused due to electric spark. The rate of metal removal and the resulting surface

4
finish can be controlled by proper variation in energy and duration of spark dis-
charge. It is the process of repetitive sparking cycles.

1.4 FEATURES OF WIRE EDM MACHINE PROCESS

Forming electrode adapted to product shape is not required.

Electrode wear is negligible.
Machined surfaces are smooth.
Geometrical & dimensional tolerances are tight.
Relative tolerance between punch & die is extremely high & die life is
extended.
Straight holes can be produced to close tolerances.
Electrical Discharge Machining machine can be operated unattended for long
time at high operating rate.
Machining is done without requiring any skills.
Any electrically conductive material can be machined irrespective of its
hardness & strength.
Electrical Discharge Machining allows the shaping of complex structures.
High machining accuracy in the order of several micrometres and achievable.
It proves to be a competitive method for ceramic processing because of the
abilities to provide accurate, cost-effective and flexible products.

1.4.1 ADVANTAGES OF WIRE EDM MACHINE

As continuously travelling wire is used as the negative electrode, so electrode

fabrication is not required as in EDM.
There is no direct contact between the work piece and the wire, eliminating the
mechanical stresses during machining.
WEDM process can be applied to all electrically conducting metals and alloys
irrespective of their melting points, hardness, toughness or brittleness.
Users can run their work pieces over night or over the weekend unattended.

5
1.4.2 DISADVANTAGES OF WIRE EDM MACHINE

High capital cost is required for WEDM process

There is a problem regarding the formation of recast layer
WEDM process exhibits very slow cutting rate
It is not applicable to very large work piece.

1.4.3 APPLICATIONS

Figure:1.4 Various shapes cut with wire cut EDM

Wire electrical discharge machining is mainly used to cut contour shapes and design
into hard metals, which are otherwise difficult to machine. Contour parts can be easily
cut with help of wire cut EDM.
Tooling elements
Automobile parts
Plastic Moulding.
Dies, Hobs Blanking.
Shear Blades.
Hot Shearing Tools.
Hardened Rolls.
Thread Rolling Dies.
Blade Cutters for Wire Nails.
Dies for Cold Nut Manufacturers Etc.

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1.5 SELECTION OF MATERIAL
We are going to use Nimonic 80A for the machining process NIMONIC alloy 80A
is a wrought, age-hard enable nickel-chromium alloy, strengthened by additions of
titanium, aluminium and carbon, developed for service at temperatures up to 815C
(1500F). It is produced by high-frequency melting and casting in air for forms to be
extruded. Electro slag refined material is used for forms to be forged. Vacuum refined
versions are also available. NIMONIC alloy 80A is currently used for gas turbine
components (blades, rings and discs), bolts, nuclear boiler tube supports, die casting
inserts and cores, and for automobile exhaust valves. The alloys limiting chemical
composition is given in Table 1.1.

Chemical composition of Nimonic 80A shown in figure below:

Table: 1.1 Chemical composition of Nimonic 80A

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 Figure 1.5: Chemical composition

Figure 1.6: Specimen before machining

Applications of Nimonic 80A

Aircraft parts

Turbine shafts

Supercar parts

Bolts and hardware components

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 CHAPTER 2
LITERATURE REVIEW

2.1 INTRODUCTION
Literature review provides help for the present study. It works as helping hand to
conduct this analysis. This chapter will play a part to get the information about wire
cut electrical discharge machine and will give idea to operate the test and Form the
early stage of the projects; various literature studies have been done. Research journals,
books, printed or online conference article were the main sources of guidance and used
as a supporting material in the project. This chapter includes almost the whole
operation including the test, history, machining properties and results. Literature
review section works as reference, to give information and guidance based on journal
and other source in the media.

2.2 LITERATURE SURVEY

Hewidy, et al. have investigated correlated the inter-relationship among various input
parameters namely peak current, duty factor, wire tension and water pressure with
output measures namely material removal rate, wear ratio and surface roughness in
wire electrical discharge machining of Inconel601. This works established based on
Response Surface Methodology (RSM). It has concluded the volumetric metal removal
rate generally increases with the increase of the peak current and water pressure, Wear
ratio increases with the increase of the peak current, Surface roughness increases with
the increase of peak current and decreases with the increase of duty factor and wire
tension. [1]

Amitesh Goswami, et al. their study consists of investigation on surface integrity,

material removal rate and wire wear ratio of Nimonic 80A using WEDM process.
Taguchi's design of experiments methodology has been used for planning and
designing the experiments. The experiment process variable at different setting of
pulse-on time, pulse-off time, spark gap set voltage, peak current, wire feed and wire
tension. L27 orthogonal array (three levels) with six input variables was selected for
experimentation. Specimen size 8mm 8mm 25mm were prepared from the block

9
using brass wire electrode of diameter 0.25 mm (Soft). De-ionized water was used as
the dielectric fluid. Results evaluate that increasing the pulse-on time and peak current
increases the material removal rate. Similarly, MRR decreases with an increased
pulse-off time and spark gap set voltage for a constant pulse-on time and peak current.
Peak current and pulse-off time are found to be the major factors affecting the wire
wear ratio. [2]

Saurav Datta, Siba Sankar Mahapatra experimented with six process parameters
are discharge current, pulse duration, pulse frequency, wire speed, wire tension and
dielectric flow rate; to be varied in three different levels. A block of D2 tool steel with
200 mm 25 mm 10 mm size. Data related to the process responses are material
removal rate (MRR), roughness value of the worked surface and kerf has been
measured for each of the experimental runs. These data have been utilized to fit a
quadratic mathematical model (Response Surface Model) for each of the responses,
which can be represented as a function of the six-process parameter. Predicted data
given by the models as per Taguchis L18 (3*6) Orthogonal Array (OA) design have
been used in search of an optimal parametric combination to achieve desired yield of
the process, maximum MRR, good surface finish and dimensional accuracy of the
product. Grey relational analysis has been adopted to convert this multi-objective
criterion into an equivalent single objective function. It has been found that that the
spark gap increases with increase in pulse on time, whereas spark gap decreases with
increase in pulse off time. The pulse on time, pulse off time, the interaction of dielectric
pressure and pulse off time, and interaction of pulse on time and pulse off time are
significant parameters which affect the spark gap of WEDM. [3]

Mustafa Ilhan, et al. aims to select the most suitable parameter combination for the
wire electrical discharge machining process in order to get the desired surface
roughness value for the machined work pieces. A series of experiments have been
performed on 1040 steel material of thicknesses 30, 60 and 80 mm, and on 2379 and
2738 steel materials of thicknesses 30 and 60 mm. The test specimens have been cut
by using different cutting and offset parameter combinations of the Sodick Mark XI
A500 EDW wire electrical discharge machine. The related tables and charts have been
prepared for 1040, 2379, 2738 steel materials. The tables and charts can be practically
used for WEDM parameter selection for the desired work piece surface roughness. And

10
finding out that increasing work piece thickness more stable & better SR
characteristics. [4]

G.Rajyalakshmi, Dr.P.Venkata Ramaiah presented experiments with eight

process parameters: pulse on time, pulse off time, corner servo voltage, wire feed, wire
tension, dielectric flow rate, spark gap voltage and servo feed to be varied in three
different levels. Data related to the process response is SR which corresponds to
randomly chosen different combinations of factor setting. These data have been
utilized to fit a mathematical model for each of the responses, which can be represented
as a function of the eight process parameters. Predicted data given by the models as
per Taguchis L18 Orthogonal Array (OA) design have been used in search of an
optimal parametric combination to achieve desired minimum roughness value. The
experiments were carried out on Ultra Cut 843/ ULTRA CUT F2 CNC WEDM
machine. The electrode material used was a 0.25 mm diameter brass wire. A small gap
of 0.025 mm to 0.05 mm is maintained in between the wire and work-piece. Inconel825
is used as work piece material. Pulse on time and wire feed rate have been most
significant effect on SR. [5]

Chiang, et al. have been investigated on Optimization of the WEDM process of

particle- reinforced material with multiple performance characteristics using grey
relational analysis employed grey relational analysis to optimize the input parameters
are pulse on time, pulse off time, arc on time, arc off time, servo voltage, wire feed and
water flow are optimized parameters for Al2O3 particle reinforced material with two
response parameters are material removal rate and surface roughness. they have
concluded the response table and response graph for each level of the machining
parameters are obtained from the grey relational grade, and select the optimal levels of
machining parameters. [6]

S Sivakiran, C. Bhaskar Reddy, C. Eswara reddy evaluated the influence of

various machining parameters Pulse on, Pulse off, Bed speed and Current on metal
removal Rate (MRR). The relationship between control parameters and Output
parameter (MRR) is developed by means of linear regression. Taguchis L16 (4*4)
Orthogonal Array (OA) /designs have been used on EN-31 tool steel to achieve
maximum metal removal rate. The experiments were performed on CONCORD

11
DK7720C four axis CNC Wire-cut electrical discharge machining (WEDM).
The results obtained are analyzed using S/N Ratios, Response table and Response
Graphs with the help of Minitab software. The better Parameter setting is Pulse on 24
sec, pulse off 6 sec, Bed speed 35 m/s and Current to obtain maximum metal
removal rate. [7]

C.D.Shah, J.R.Mevada, B.C.Khatri the study is made to optimize the process

parameters during machining of Inconnel-600 by wire electrical discharge machining
(WEDM) using response surface methodology (RSM). Four input process parameters
of WEDM namely Peak Current, Pulse-On time, Pulse-Off time and Wire Feed rate
were chosen as variables to study the process performance in terms of Material
Removal Rate. In that work, the parametric optimization method using Taguchis
robust design is proposed for wire-cut electric discharge machining of Inconel-600.
So, experimentation has been done by using Taguchis Mixed L18 (2133) orthogonal
array. Each experiment was conducted under different conditions of pulse on time,
pulse off time, peak current, and wire feed rate. The response of material removal rate
is considered for improving the machining efficiency. Optimal combinations of
parameters were obtained by this method. The level of importance of the machining
parameters on the material removal rate is determined by using ANOVA and it is
shown that Pulse on, pulse off, Peak current are most significant. And also conclude
that the cutting rate increases with the increase of pulse on time and peak current, and
decreases with increase in pulse off time. [8]

Y. S. Sable, R.B Patil, Kadam. evaluated the effect of wire electrical discharge
machining parameters on WC-10%Co sintered composite is studied. Influence of
pulse-on time, pulse-off time, peak current, servo voltage and wire tension are
investigated for surface roughness during machining of Tungsten Carbide Cobalt
sintered composite. In order to analyse the effect of process parameter on response
characteristics Response surface methodology is used. In that, work on a 5-axis CNC
WEDM, Electronica Machine Tools Ltd., India, SPRINT CUT-734 was used for the
study. Brass wire electrode of 0.25 mm diameter employed as tool electrode, distilled
water used as cooling media. From the percentage of contribution it is clear that
contribution or effect of Pulse on time higher 49.94 % and below to that Servo voltage
41.86 % hence most significant. Peak current and Pulse off time having contribution

12
4.09 %, 3.34 %, respectively hence significant. Wire tension having percentage of
contribution is 0.00 % hence it is not significant. The surface roughness is most affected
by the amount of discharge energy which increases with increase in pulse on-time. [9]

Anish Kumar, et al. presented study in the wire breakage frequency in the WEDM
process. Many factors have effect on the process of WEDM including electrical
parameters and electrode. But wire breakage frequency in the WEDM process
decreases the productivity and quality of machined surface. In this study, the effect of
six input parameters i.e. TON, TOFF, Ip, SV, WF and WT on wire breakage frequency
and the surface integrity of wear out wire during machining of pure titanium. The
experiments were performed on a 4-axis computer numerical control type wire electric
discharge machine. The effect of pulse on time on the wire breaking frequency
indicating that the wire breakage frequency continuously increases with an increase in
pulse on time. When the value of pulse on time is minimum then there is no wire
breakage during the WEDM of pure titanium, but as the pulse on time increases, the
probability of wire breakage starts increasing due to increase of discharge rate. Wire
rupturing was observed at higher values of peak current and spark frequency. [10]

Thella Babu Rao, A.Gopala Krishna investigated the formulation of kerf width and
optimal control parameter settings of wire electric discharge machining which
results minimum possible kerf while machining Al7075/SiCp MMCs. A response
surface model is used to predict the relative significance of various control variables
on kerf. Consequently, a powerful artificial intelligence called genetic algorithms (GA)
is used to determine the best combination of the control variable settings. The
Taguchis design of experiments (DOE) is employed to minimize the number of
experimental runs and the experiments are designed for L27 orthogonal array. The
MMCs are produced with different particulate sizes as 25, 50 and 75m reinforced
each at distinct volume fractions as 5, 10 and 15%. The parameters Pulse-on time,
pulse-off time and wire tension were selected as WEDM process parameters in addition
to the composite variables of particulate size and volume fraction of SiCp. Evaluate
that, the Kerf width is greatly affected by the pulse-on time. And also, the kerf width
is affected by the pulse-off time but is in negative as compared to pulse-on time.
Finding that for the higher volume of reinforcement in combination with increased
pulse-off time reduces the kerf. [11]

13
Bijendra Diwakar, et al. their research is based on the Taguchi methodology found
the optimum process parameters for CNC wire electric discharge machining (WEDM).
The object of the research paper to optimize the MRR and SR of work piece high
chromium high carbon (HCHC) die steel tool. This methodology based on Taguchis,
analysis of variance (ANOVA) and signal to noise ratio (S/N Ratio) to optimize the
CNC WEDM process parameter. The design of experiment for machining process
control parameter are Voltage, Discharge current, Pulse duration, Pulse frequency and
Wire Tension L27 (3*5) standard orthogonal array design of experiment three level
and five parameters respectively for each combination conducted one experiment.
Based on Taguchi analysis for Material removal rate, pulse frequency is the most
significant factor. In the case of surface roughness pulse duration is the most significant
factor in case of SR. [12]

14
 CHAPTER 3
DESIGN OF EXPERIMENT

3.1 WEDM PROCESS PARAMETERS

The process parameters that can affect the quality of machining or cutting or drilling
in Wire EDM process are shown through Ishikawa cause effect diagram as shown in
Figure 3.1. The major parameters are as follows: -
Electrical parameters: Peak current, pulse on time, pulse off time, supply voltage and
polarity.
Non electrical parameters: wire speed; work feed rate, machining time, gain and
rate of flushing.
Electrode based parameters: Material and size of wire.
Dielectric system: Type, viscosity and other flow characteristics.

Figure 3.1: Ishikawa Cause and Effect Diagram for WEDM Process

15
3.2 PROCESS PARAMETERS

Throughout this dissertation work input parameters considered for Wire cut EDM are
machining parameters like as pulse on time, pulse off time, flushing pressure, servo
voltage, wire feed rate, wire tension and output parameters are surface roughness, kerf
width and material removal rate.

3.2.1 INPUT PARAMETERS

I. Pulse on time (Ton)

During WEDM all the work is done during pulse duration (On time). The erosion rates
are affected mainly by pulse parameter. The spark gap is bridged, current is generated
and the work is accomplished. The longer the spark is sustained, the higher is the
material removal. Consequently, the resulting craters will be broader and deeper
therefore, the surface finish will be rougher. Obviously with shorter duration of sparks
the surface finish will be better.

Figure 3.2: Shows peak current, pulse-off time and on time

16
II. Pulse off time (Toff)
While most of the machining takes place during on time of the pulse, the off time
during which the pulse rests and the re-ionization of the die-electric takes place, can
affect the speed of the operation in a large way. Longer is the off time greater will be
the machining time. But this is an integral part of the EDM process and must exist. The
off time also governs the stability of the process. An insufficient off time can lead to
erratic cycling and retraction of the advancing servo, slowing down the operation cycle.
In addition, the interval time also provides the time to clear the disintegrated particles
from the gap between the electrode and work piece for efficient cut removal. Too short
pulse interval will increase the relative wear ratio and will increase the surface
roughness of the machine surface.

III. Gap voltage (Gv)

Gap voltage is also another important primary input of WEDM process. The voltage
determines the width of spark gap between the leading edge of the electrode and the
work piece. High voltage setting increases the gap of machining.

IV. Flushing pressure (Fp)

Flushing pressure is important to achieve a stable machining condition. Its play
important role as far as cutting speed is concerned. both the nozzles (upper and lower)
should be just about 0.1-0.2 mm away from the work piece, otherwise cutting
performance drops considerably. Also, the both nozzle should be checked periodically
for damages.

V. Wire feed rate (Wf)

The rate at which the wire electrode travels and continuously fed along the wire guide
path for continuous sparking is called wire feed. Maximum wire feed is required in
order to avoid wire breakage, to have better machining and better material removal
rates.

17
VI. Wire tension (Wt)
The amount of stretch in the wire between the upper and lower wire guides is called
the wire tension and it is measured as gram equivalent load. In order to keep wire
straight between two guides wire is kept continuously kept under tension. Wire tension
is directly proportional to the thickness of the work piece, i.e. more the thickness of
workpiece more the tension required. Improper setting of tension may result in the
inaccuracies as well as wire breakage.

3.2.2 RESPONSE VARIABLES

WEDM performance is generally determined by the material removal rate (MRR) and
surface roughness of the work piece that has been machined. The process parameters
should be chosen properly so as to have maximum MRR, minimum roughness value
and minimum wire wear rate.
The response variables for WEDM process are discussed below.

I. Material removal rate (MRR)

The material removal rate (MRR) of the work piece is the amount of the material
removed per minute. MRR and Cutting speed capabilities of WEDM have increased
enormously over the years. They are influenced by the age and type of machine along
with the properties and characteristics of the work piece being cut. The machine
settings set by the operator and programmer also affect the MRR and cutting speed.

II. Surface roughness (SR) or surface finish

The smoothness of the part surface machined by a given process is referred to as
surface finish. No standard has been universally adopted for measuring the surface
finish of parts. The general units opted are Ra (roughness average), RMS (root mean
square). Both are measured in (m).

III. Wire Wear Rate (WWR)

The removal of the material of the wire that is being used for machining. The change
in the dimension of the wire that is being used for machining is calculated by using the
wear ratio. More the change in the dimension of the wire more is the tool wear. The
aim should be to reduce the tool wear.

18
3.3 GENERATION OF DESIGN OF EXPERIMENTS

3.3.1 INTRODUCTION

Design of Experiments (DOE) techniques enables designers to determine

simultaneously the individual and interactive effects of many factors that could affect
the output results in any design. DOE also provides a full insight of interaction between
design elements. The design of experiments (DOE) is an efficient procedure for
planning experiments so that they obtained data can be analyzed to yield valid and
objective conclusions. DOE begins with determining the objectives of an experiment
and selecting the process factors for the study. An Experimental Design is the laying
out of a detailed experimental plan in advance of doing the experiment. Well-chosen
experimental designs maximize the amount of "information" that can be obtained for a
given amount of experimental effort.

3.3.2 METHODS OF DOE

Following methods are used in design of experiment.

1. Taguchi Method
2. Factorial Method
3. Response Surface Method

Here we are going to use the Response surface method.

Response surface methodology (RSM) explores the relationships between

several explanatory variables and one or more response variables. The method was
introduced by G. E. P. Box and K. B. Wilson in 1951. The main idea of RSM is to use
a sequence of designed experiments to obtain an optimal response. Box and Wilson
suggest using a second-degree polynomial model to do this. They acknowledge that
this model is only an approximation, but use it because such a model is easy to estimate
and apply, even when little is known about the process.

Statistical approaches such as RSM can be employed to maximize the production of a

special substance by optimization of operational factors. In contrast to conventional

19
methods, the interaction among process variables can be determined by statistical
techniques.

The steps for fitting a response surface (second-order or quadratic) model are as
follows:

1.Fit the full model to the first response.

2.Use stepwise regression, forward selection, or backward elimination to identify

important variables.

3.When selecting variables for inclusion in the model, follow the hierarchy principle
and keep all main effects that are part of significant higher-order terms or interactions,
even if the main effect p-value is larger than you would like (note that not all analysts
agree with this principle).

4.Generate diagnostic residual plots (histograms, box plots, normal plots, etc.) for the
model selected.

5.Examine the fitted model plot, interaction plots, and ANOVA statistics (R2, adjusted
R2, lack-of-fit test, etc.). Use all these plots and statistics to determine whether the
model fit is satisfactory.

6.Use contour plots of the response surface to explore the effect of changing factor
levels on the response.

7.Repeat all the above steps for the second response variable.

8.After satisfactory models have been fit to both responses, you can overlay the surface
contours for both responses.

9.Find optimal factor settings.

20
3.3.3 KEY TERMS IN DOE

1. Factors
These are variables that have direct influence on the performance of the product or
process under investigation.

Factors are of two types:

(a) Discrete - Assumes known values or status for the level. Example:
Container, Vendor, Type of materials, etc.
(b) Continuous - Can assume any workable value for the factor Levels. Example:
Temperature, Pressure, Thickness, etc.

2. Levels
This is the values or descriptions that define the condition of the factor held while
performing the experiments.

3.4 INPUT PARAMETERS

Factor A: duty factor

duty factor (D) = (pulse-on time/ (pulse-on time + pulse-off time).
Factor B: wire feed rate (M/min)
Factor C: Gap voltage (V)

3.5 FACTORS WITH LEVELS

Table 3.1: factors with their levels

21
3.6 FIXED VALUES

There are many factors that are kept constant such variables are shown in the table
below:
Table: 3.2 Fixed Variables

Sr. No. Fixed Parameters Set Value

1 Work material Nimonic 80A
2 Tool wire material (.025mm) Molybdenum
3 Peak current (amp) 4
4 SEN 10
5 Dielectric fluid Deionized water

As per Table, Central composite method of Response surface method has been
selected for the experiments design in MINITAB 17.

Table: 3.3 Data sheet

The design of experiments was conducted with using MINITAB17 software.

22
 CHAPTER 4
EXPERIMENT WORK AND MEASUREMENT

4.1 INTRODUCTION

The experimental setup and the experiment is designed and carried out at Machine shop
(SRM university). The primary goal of the dissertation work is to predict the MRR,
surface roughness, and Wire wear rate. The work is carried out in Ezeecut plus wire
cut electro discharge machine of Nimonic 80A material by varying machining
parameters. The Ezeecut plus wire cut electric discharge machine is comprised of a
machine tool, a power supply unit and dielectric supply unit. The most operations
handle by the automatic control system as programmed by the operator. A schematic
diagram of the Ezeecut plus wire cut EDM is shown in Fig. 4.1.

Figure 4.1: Ezeecut wire EDM machine

23
Specifications of machine are shown in the table given below table 4.1

Table 4.1: Machine specification

Specifications of machine

Worktable size: 680*500 mm

XY table traverse: 300x400 mm

Max Z height: 480mm

Max workpiece weight: 300kgs

Max taper cutting angle: 3 at 100 mm job height

Maximum tool weight: 1400kg

Wire diameter: 0.12 to 0.25 mm

Best surface finish: 1-15 microns

Maximum cutting speed: 60 mm/min

Generator Ez-01

Display Colour TFT

Min. input command: 0.001 mm

Min increment: 0.001 mm

interpolation function: Linear & Circular

Data input/Output: CD drive / USB drive

input power supply: 3 phase,415 VAC, 50 Hz

Connected load: 15 kVA Dielectric Unit

Dielectric fluid: Tap water + Coolant oil (20:1)

Tank capacity: 55 Litres

24
 Figure 4.2: Fixing the component for machining

4.2 MACHINING CHARACTERISTICS:

There are only three characteristic measures which are listed below:
1) Surface Roughness
2) wire wear rate
3) Material Removal Rate

4.2.1 SURFACE ROUGHNESS

Surface roughness values of finished work pieces were measured by surfcom 1400 g
by a proper procedure. The surfcom 1400 g 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. Its
output is a digital display of measured Surface roughness value Ra and other features.
Surface Roughness Standard ISO was used for measurement. In this present study, we

25
have taken Ra for measuring Surface Roughness. The total of 4 mm of measurement
was done on the specimen with the speed of 0.300 mm/s.

Surfcom 1400g specifications are shown below in the figu

Figure 4.3 Specification of surfcom 1400g

Figure 4.4 : Testing the surface roughness

26
4.2.2 MATERIAL REMOVAL RATE:

The material removal rate is calculated by using (Weight of workpiece before

machining Weight of workpiece aftermachining)/(Time).

MRR unit: (Gram/minute)

Sample MRR calculation:

Initial weight: 1.476kg

After machining weight: 1.462kg and the weight of cut specimen: 13.1665g
So initial weight final weight = 1.476-(1.462+0.0131665) = 0.8335 gms
Time taken to machine: 15.59 minute
MRR =( 0.8335/16) = 0.0520938 gms/min

Figure 4.5: Machined work piece at the machining site

27
4.2.3 WIRE WEAR RATE

The wire wear rate is calculated by using wire wear formula

((initial wire weight- Final wire weight)/Initial wire weight).

Sample WWR calculation:

Initial weight of wire=31.03050 gms

The weight of wire after machining= 25.56292 gms
WWR formula= ((initial wire weight- Final wire weight)/Initial wire
weight).

= ((31.03050-25.56292)/31.03050)

= 0.13513478

4.2.4 FINAL DATA WITH CALCULATION

Table 4.2: Data sheet with calculation

28
 CHAPTER 5
OPTIMIZATION WITH RESPONSE SURFACE
METHOD

5.1 ANOVA ANALYSIS

5.1.1 INTRODUCTION

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. 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. The technique does not directly analyse the data,
but rather determines the variability (variance) of the data. Analysis provides the
variance of controllable and noise factors. By understanding the source and magnitude
of variance, robust operating conditions can be predicted.

5.1.2 ANOVA NOTATIONS

In the analysis of variance many quantities such as degrees of freedom, sums of

squares, mean squares, etc., are computed and organized in a standard tabular format.
C.F. = Correction factor n = Number of trials
r = Number of repetition e = Error
P = Percent contribution F = Variance ratio
T = Total of results f = Degree of freedom
S = Sum of squares fe= Degree of freedom of error
S= Pure sum of squares fT = Total degree of freedom
V= Mean squares (variance)
Total number of trials: The total number of trials is the sum of trials at each
level.
Degree of freedom: It is a measure of the amount of information that can be
uniquely determined from a given set of data. DOF for data concerning a factor
equals one less than the number of levels.

29
 Sum of squares: The sum of squares is a measure of the deviation of the
experimental data from the mean value of the data.
Variance: Variance measures the distribution of the data about the mean of the
data.

Variance ratio: Variance ratio is the ratio of variance due to effect of a factor
and variance due to the error term. This ratio is used to measure the significance
of the factor under investigation with respect to the variance of all the factors
included in the error term. The F value obtained in the analysis is compared
with a value from standard F- tables for a given level of significance. When the
computed F value is less than the value determined from the F tables at the
selected level of significance, the factor does not contribute to the sum of
squares within the confidence level.

5.1.3 ANOVA FOR MATERIAL REMOVAL RATE

In this research work, according to design of experiment using central composite

design, 20 experimental runs are carried out on work piece. For design of experiment,
2-levels of each factor is used.

Table 5.1: Factors with parameters

30
 Table 5.2 : ANOVA table for MRR

Regression Equation in Uncoded Units for MRR:

MRR = 1.75 - 5.40 Duty Factor - 0.0534 Gap Voltage + 0.02719 Feed Rate
+ 5.33 Duty Factor*Duty Factor + 0.00266 Gap Voltage*Gap Voltage
- 0.000019 Feed Rate*Feed Rate - 0.0723 Duty Factor*Gap Voltage
- 0.03229 Duty Factor*Feed Rate + 0.000249 Gap Voltage*Feed Rate

31
The regression plot (The normality plot) For MRR is shown below:

Figure 5.1: Normal plot of MRR

The normality plot shows how much residual is there per experiment in case of MRR
we can see that there is very less deflection from the normal probability line.

5.1.4 ANOVA FOR WIRE WEAR RATE

Table 5.2: ANOVA table for WWR

32
Regression Equation in Uncoded Units for WWR

WWR = -4.28 + 0.00 Duty Factor + 0.2651 Gap Voltage + 0.0526 Feed Rate
+ 2.02 Duty Factor*Duty Factor - 0.00186 Gap Voltage*Gap Voltage
- 0.000117 Feed Rate*Feed Rate - 0.1243 Duty Factor*Gap Voltage
- 0.0183 Duty Factor*Feed Rate - 0.001041 Gap Voltage*Feed Rate

The regression plot for WWR is as follows:

Figure 5.2: Normal plot for WWR

The normality plot shows how much residual is there per experiment in case of WWR
we can see that there is very less deflection from the normal probability line.

33
5.1.5 ANOVA FOR SURFACE ROUGHNESS

Table 5.3: ANOVA for surface roughness

Regression Equation in Uncoded Units for surface roughness

SR = -209.6 + 271.0 Duty Factor + 6.28 Gap Voltage + 0.887 Feed Rate
- 95.8 Duty Factor*Duty Factor - 0.0668 Gap Voltage*Gap Voltage
- 0.002640 Feed Rate*Feed Rate - 3.93 Duty Factor*Gap Voltage
- 0.396 Duty Factor*Feed Rate - 0.00386 Gap Voltage*Feed Rate

34
The regression plot for SR is as follows:

Figure 5.3: Normal plot for surface roughness

The normality plot shows how much residual is there per experiment in case of surface
roughness we can see that there is very less deflection from the normal probability line.

35
5.2 CONTOUR PLOTS

5.2.1 CONTOUR PLOTS FOR MRR

Contour Plot of MRR vs Gap Voltage, Duty Factor

20
MRR
< 0.02
0.02 0.03
0.03 0.04
19 0.04 0.05
0.05 0.06
0.06 0.07
> 0.07
Gap Voltage

18 Hold Values
Feed Rate 82.5

17

16

15
0.82 0.84 0.86 0.88 0.90 0.92 0.94
Duty Factor

Figure 5.4: Contour plot MRR vs Gap voltage, duty factor

The above-mentioned contour plot (figure 5.4) shows the effect of the interaction of
the gap voltage and the duty factor on the MRR. We can see from the plot that as we
increase the duty factor value there is increase in the MRR. And as we increase the gap
voltage there is decrease for first few value and then there is increase in the value of
MRR. The contour plot is basically a 3-d surface plot converted into 2-d the surface
which shows the blue patch has the minimum MRR that means the interaction points
that of Gap voltage and duty factors that lie in the blue patch will provide minimum
MRR.

Contour Plot of MRR vs Feed Rate, Gap Voltage

100
MRR
< 0.01
0.01 0.02
95
0.02 0.03
0.03 0.04
> 0.04
90
Hold Values
Duty Factor 0.877105
Feed Rate

85

80

75

70

65
15 16 17 18 19 20
Gap Voltage

Figure 5.5: Contour plot MRR vs feed rate, Gap voltage

36
The above-mentioned contour plot (figure 5.5) shows the effect of the interaction of
the feed rate and the gap voltage on the MRR. We can see from the plot that as we
increase the feed rate value there is increase in the MRR. And as we increase the gap
voltage there is decrease value of MRR.

Contour Plot of MRR vs Feed Rate, Duty Factor

100
MRR
< 0.000
0.000 0.015
95
0.015 0.030
0.030 0.045
0.045 0.060
90 > 0.060

Hold Values
Gap Voltage 17.5
Feed Rate

85

80

75

70

65
0.82 0.84 0.86 0.88 0.90 0.92 0.94
Duty Factor

Figure 5.6: Contour plot MRR vs feed rate, Duty factor

The above-mentioned contour plot (figure 5.6) shows the effect of the interaction of
the feed rate and the duty factor on the MRR. We can see from the plot that as we
increase the feed rate value there is increase in the MRR. And as we increase the duty
factor there is increase value of MRR.

37
5.2.2 CONTOUR PLOTS FOR WWR

Contour Plot of WWR vs Feed Rate, Gap Voltage

100
WWR
< 0.06
0.06 0.08
95
0.08 0.10
0.10 0.12
0.12 0.14
90 0.14 0.16
0.16 0.18
> 0.18
Feed Rate

85
Hold Values
Duty Factor 0.877105
80

75

70

65
15 16 17 18 19 20
Gap Voltage

Figure 5.7: Contour plot of WWR vs feed rate, Gap voltage

The above-mentioned contour plot (figure 5.7) shows the effect of the interaction of
the feed rate and the gap voltage on the WWR. We can see from the plot that as we
increase the feed rate value there is increase in the WWR. And as we increase the Gap
voltage there is increase value of WWR.

Contour Plot of WWR vs Feed Rate, Duty Factor

100
WWR
< 0.10
0.10 0.12
95
0.12 0.14
0.14 0.16
> 0.16
90
Hold Values
Gap Voltage 17.5
Feed Rate

85

80

75

70

65
0.82 0.84 0.86 0.88 0.90 0.92 0.94
Duty Factor

Figure 5.8: contour plot of WWR vs feed rate, Duty factor

The above-mentioned contour plot (figure 5.8) shows the effect of the interaction of
the feed rate and the Duty factor on the WWR. We can see from the plot that as we

38
increase the feed rate value there is increase in the WWR. And as we increase the duty
factor there is increase value of WWR.

Contour Plot of WWR vs Gap Voltage, Duty Factor

20
WWR
< 0.13
0.13 0.14
0.14 0.15
19 0.15 0.16
0.16 0.17
0.17 0.18
0.18 0.19
> 0.19
Gap Voltage

18
Hold Values
Feed Rate 82.5

17

16

15
0.82 0.84 0.86 0.88 0.90 0.92 0.94
Duty Factor

Figure 5.9: Contour plot of WWR vs Gap voltage, Duty factor

The above-mentioned contour plot (figure 5.9) shows the effect of the interaction of
the Gap voltage and the Duty factor on the WWR. We can see from the plot that as we
increase the gap voltage value there is increase in the WWR. And as we increase the
duty factor there is increase value of WWR.

39
5.2.3 CONTOUR PLOTS FOR SURFACE ROUGHNESS

Contour Plot of SR vs Feed Rate, Gap Voltage

100
SR
< 2.5
2.5 3.0
95
3.0 3.5
3.5 4.0
4.0 4.5
90 > 4.5

Hold Values
Duty Factor 0.877105
Feed Rate

85

80

75

70

65
15 16 17 18 19 20
Gap Voltage

Figure 5.10: Contour plot of surface roughness vs Gap voltage, Duty factor

The above-mentioned contour plot (figure 5.10) shows the effect of the interaction of
the Gap voltage and the feed rate on the surface roughness. We can see from the plot
that as we increase the gap voltage value there is increase in the surface roughness.
And as we increase the feed rate there is increase value of surface roughness.

Contour Plot of SR vs Feed Rate, Duty Factor

100
SR
< 2.5
2.5 3.0
95
3.0 3.5
3.5 4.0
4.0 4.5
90 > 4.5

Hold Values
Gap Voltage 17.5
Feed Rate

85

80

75

70

65
0.82 0.84 0.86 0.88 0.90 0.92 0.94
Duty Factor

Figure 5.11: contour plot of surface roughness vs feed rate, Duty factor

The above-mentioned contour plot (figure 5.11) shows the effect of the interaction of
the duty factor and the feed rate on the surface roughness. We can see from the plot

40
that as we increase the feed rate value there is increase in the surface roughness. And
as we increase the duty factor there is increase value of surface roughness.

Contour Plot of SR vs Gap Voltage, Duty Factor

20
SR
< 2.5
2.5 3.0
3.0 3.5
19 3.5 4.0
4.0 4.5
> 4.5

Hold Values
Gap Voltage

18 Feed Rate 82.5

17

16

15
0.82 0.84 0.86 0.88 0.90 0.92 0.94
Duty Factor

Figure 5.12: Contour plot of surface roughness vs gap voltage, Duty factor

The above-mentioned contour plot (figure 5.12) shows the effect of the interaction of
the duty factor and the gap voltage on the surface roughness. We can see from the plot
that as we increase the gap voltage value there is increase in the surface roughness.
And as we increase the duty factor there is increase value of surface roughness.

41
5.3 RESULT OPTIMISER:

Figure 5.13: Response optimizer

The figure 5.13 shows the responses optimizer the tool which is used to optimize the
parameters as per our requirement. Here we want the MRR to be maximum and surface
roughness and WWR to be minimum, so we will set the optimizer with such response
requirement.

42
 Figure 5.14: Optimized response

The figure 5.14 shows the optimized response for the given response now the Graph
shows the individual effect of each input parameters on output response as well as it
also shows the interaction of the all the three parameters which are suitable to find the
optimum solution and to get the minimum WWR, surface roughness and maximum
MRR at the same time.

The optimized parameters for our process are:

Duty factor 0.8885
Gap voltage 15V
Feed rate 65 m/min

43
 CHAPTER 6
GREY RELATIONAL BASED MULTI RESPONSE
OPTIMIZATION

6.1 INTRODUCTION
It is used to study the effects of input parameters on response variables. This quality
analysis tool analyses the obtained results by using signal-to-noise (S / N) ratio. This
ratio is determined by characteristics of the machining process. The categories of this
ratio are larger the better, smaller the better and nominal the better. In EDM process,
the main aim is to reduce surface Roughness, wire wear rate and to increase material
removal rate. Hence, Larger the better has been applied for material removal rate
(MRR) whereas the smaller the better has been applied for surface roughness (SR) and
wire wear rate(WWR).

6.2 FORMULATION FOR SN RATIO

For Larger the better,

S/N ratio = - 10 log (1/n) ( 1 / Yij2 )

For smaller the better,

S/N ratio = - 10 log (1/n) (Yij2 )

Where n is the number of replications for each experiment and Yij is the response
values.

6.3 GREY RELATIONAL APPROACH

In the present study, the multiple performance characteristics have been investigated
with grey relational approach. In this method, the multiple performance characteristics
can be converted into single grey relational grade. The following stages are
done for this approach:

44
Step 1
The S/N ratios obtained from the analysis have to be normalized in the range of 0 to 1.

For larger the better,

Xij = (Yij min (Yij)) / (max (Yij) min (Yij) )

For smaller the better,

Xij = (max(Yij) Yij) / (max (Yij) min (Yij ) )

Where Xij is normalized S/N ratio, Yij is the S/N ratio obtained from the analysis,
min(Yij) and max(Yij) are respectively minimum and maximum values of S/N ratio.

Step 2
Grey relational grade in this analysis indicates the relational degree between every
sequence of obtained values. The grey relational coefficient can be calculated as:
GCij = (min + max ) / (ij + max )
Where GCij is the grey relational grade. Since multi response characteristics consist of
both larger the better and smaller the better, is assumed to 0.5 in this case. min and
max are the minimum and maximum absolute difference which is a deviation from
target value and can be treated as quality loss.

Step 3
After averaging the grey relational coefficients, grey relational grade (Gi) can be
calculated as:
Gi = (1/m) GCij

Where m is the number of response variables. The high value of grey relational grade
indicates the stronger relational degree between ideal sequence and present sequence.
Ideal sequence is the best response in the machining process. Higher grey grade
indicates closer to the optimal response in the process.

45
6.3.1 CALCULATION FOR GREY RELATIONAL COEFFICIENT

The table below (6.1) shows the calculation and tabulation of the WWR response that
has been converted into Grey relational coefficient.

Table 6.1: Grey relational coefficients of WWR

WWR S/N ratio Normalised 1-Normalised GCI
0.13513478 17.38465722 0.573531198 0.426468802 0.53968358
0.1713 15.32485274 0.954671324 0.045328676 0.916878246
0.112186397 19.00119597 0.274411651 0.725588349 0.407967325
0.136897569 17.27208531 0.594361171 0.405638829 0.552096469
0.127648604 17.87967862 0.481933903 0.518066097 0.491127247
0.154141893 16.24158625 0.785041667 0.214958333 0.699341454
0.123014454 18.20087717 0.422500274 0.577499726 0.464037241
0.141493047 16.98529801 0.647427445 0.352572555 0.586460351
0.163471423 15.73116312 0.879488853 0.120511147 0.805787298
0.169894136 15.3964322 0.941426473 0.058573527 0.895137303
xx0.145479448 16.74396713 0.692082596 0.307917404 0.618875144
0.169571873 15.41292367 0.93837494 0.06162506 0.890273665
0.094577915 20.48420526 0 1 0.333333333
0.144232288 16.81875017 0.678244965 0.321755035 0.608453832
0.148821321 16.5466969 0.728584897 0.271415103 0.648159464
0.1762 15.07988192 1 0 1
0.149597976 16.50148563 0.736950655 0.263049345 0.655265617
0.162991259 15.75671374 0.874761043 0.125238957 0.799694252
0.132405214 17.56189824 0.540735045 0.459264955 0.521232426
0.175878571 15.09574143 0.997065403 0.002934597 0.994165053

46
The table below (6.2) shows the calculations of grey relational coefficient for surface
roughness.
Table 6.2: Grey relational coefficient for Surface roughness

SR S/N ratio Normalised 1-Normalised GCI

3.4078 -10.64948197 0.665806326 0.334193674 0.599381194
4.4299 -12.92787845 0.227863881 0.772136119 0.393039701
4.4033 -12.87556551 0.237919225 0.762080775 0.396171156
4.1148 -12.28697462 0.351055341 0.648944659 0.43518197
3.049 -9.683148487 0.851550314 0.148449686 0.771069847
3.8301 -11.66420226 0.470761658 0.529238342 0.485796127
3.7684 -11.5231399 0.497875988 0.502124012 0.498940245
5.0777 -14.11334077 0 1 0.333333333
4.0333 -12.11321053 0.384455443 0.615544557 0.44821159
4.4542 -12.97539427 0.218730618 0.781269382 0.390237999
4.3245 -12.71871803 0.268067695 0.731932305 0.405866457
4.4208 -12.91001735 0.231297056 0.768702944 0.394103287
3.9968 -12.03424833 0.399633177 0.600366823 0.454393925
4.0454 -12.1392294 0.379454219 0.620545781 0.446211131
4.5976 -13.25062368 0.165827341 0.834172659 0.374764088
4.3816 -12.83265456 0.246167361 0.753832639 0.398777305
4.491 -13.0468611 0.204993607 0.795006393 0.38609848
3.499 -10.87887885 0.621712758 0.378287242 0.569289836
2.7896 -8.910838687 1 0 1
3.9129 -11.84997498 0.435053317 0.564946683 0.469507073

47
The table below 6.3 shows the calculation as well as the grey relational coefficient for
MRR.

Table 6.3: Grey relational coefficients for MRR

MRR (g/min) S/N ratio Normalised 1- Normalised GCI
0.05209375 -25.66428757 0 1 0.333333333
0.05018 -25.98938686 0.019361261 0.980638739 0.337692097
0.01082 -39.31545478 0.812994136 0.187005864 0.727795826
0.01612777 -35.84851357 0.606520739 0.393479261 0.559610079
0.02410126 -32.35920504 0.398715257 0.601284743 0.454015188
0.03801142 -28.40171812 0.16302745 0.83697255 0.373979256
0.0403139 -27.89090372 0.132605941 0.867394059 0.365659041
0.047156 -26.52926082 0.05151341 0.94848659 0.34518787
0.03044667 -30.329204 0.277818713 0.722181287 0.409104611
0.008704545 -41.2050785 0.92553052 0.07446948 0.870368258
0.0139529 -37.10671037 0.099462695 0.900537305 0.357005842
0.017981171 -34.90364082 0.55024892 0.44975108 0.526453731
0.0088131 -41.09742604 0.919119287 0.080880713 0.860761924
0.0251214 -31.99912323 0.377270614 0.622729386 0.445343291
0.0309462 -30.18785344 0.269400592 0.730599408 0.406306062
0.0190711 -34.39248513 0.519807085 0.480192915 0.510103667
0.007669 -42.30522524 0.991049669 0.008950331 0.982414136
0.027127 -31.33196465 0.337538041 0.662461959 0.430121602
0.007537449 -42.45551227 1 0 1
0.0128415 -37.82768488 0.724390122 0.275609878 0.644653987

48
6.3.2 FINAL GREY AVERAGE COEFFICIENT AND RANK

The table 6.4 shows the average grey relational analysis coefficients and ranks.

Table 6.4: Ranks after optimization

Trial no GCI MRR GCI SR GCI WWR Grade Rank
1 0.333333333 0.599381194 0.53968358 0.490799369 16
2 0.337692097 0.393039701 0.916878246 0.549203348 11
3 0.727795826 0.396171156 0.407967325 0.510644769 14
4 0.559610079 0.43518197 0.552096469 0.515629506 13
5 0.454015188 0.771069847 0.491127247 0.572070761 8
6 0.373979256 0.485796127 0.699341454 0.519705612 12
7 0.365659041 0.498940245 0.464037241 0.442878842 19
8 0.34518787 0.333333333 0.586460351 0.421660518 20
9 0.409104611 0.44821159 0.805787298 0.554367833 9
10 0.870368258 0.390237999 0.895137303 0.718581187 2
11 0.357005842 0.405866457 0.618875144 0.460582481 18
12 0.526453731 0.394103287 0.890273665 0.603610228 6
13 0.860761924 0.454393925 0.333333333 0.549496394 10
14 0.445343291 0.446211131 0.608453832 0.500002751 15
15 0.406306062 0.374764088 0.648159464 0.476409872 17
16 0.510103667 0.398777305 1 0.636293657 5
17 0.982414136 0.38609848 0.655265617 0.674592744 4
18 0.430121602 0.569289836 0.799694252 0.599701897 7
19 1 1 0.521232426 0.840410809 1
20 0.644653987 0.469507073 0.994165053 0.702775371 3

The final result that we get after the optimization is that trial no.19 is the optimum one
which fulfils all the 3 conditions that is minimum WWR and surface roughness as well
as maximum MRR.

The optimum Reading is gap voltage 17V, Feed rate 65 m/min, Duty Factor-0.877193

49
6.4 CONFIRMATION EXPERIMENT

After analysing the experimental values by grey-relational multi response analysis we

have found an optimum value which is suitable for controlling all the 3 responses that
are material removal rate, wire wear rate, surface roughness. The trial no. 19 is the
optimum reading. We are going to conduct a confirmation experiment based on the
parameters of trial 19 and find out the error existing in the reading.

The final confirmation experiment was conducted and is tabulated below:

Table 6.5: Confirmation experiment

Optimize value of input parameters Previous
Current
Response Experimental % error
Feed rate Gap voltage experiment value
Duty factor value
(m/min) (V)

MRR (G/min) 0.877193 65 17 0.0075374 0.0078363 3.96

SR, Ra
(m) 0.877193 65 17 2.7896 2.8497 2.15

WWR 0.877193 65 17 0.132405 0.130368 1.53

The confirmation test suggest that the values are having very minor errors in the
confirmation test. So, we can conclude that the parameters of trial 19 are the best
parameters for machining any component

50
 CHAPTER 7
CONCLUSION

The 20 experiments were conducted using response surface method with using
Nimonic 80A material and using molybdenum wire of (0.25mm) as tool. There are
many conclusions made from the above study. The duty factor has the most dominating
effect on MRR, surface roughness and wire wear rate. As there is increase in the value
of duty factor there is rise and increase in the value of MRR, surface roughness and wire
wear rate. The reason behind such result is that duty factor is the prime input parameter
the duty factor controls the pulse on time as well as pulse off time. So, we can directly
tell that increase in duty factor will increase the exposure of spark field to the work
piece as well as the tool wire. So, with increase in the duty factor there is increase in all
the three factors.

The effect of feed rate has also been predominant in the study. Feed rate is seen to be
directly proportional to the MRR, surface roughness and Wire wear rate. As there is
increase in the feed rate there is increase in the all the 3 factors. The reason behind such
result is the nature of the input parameter. The feed rate is the rate of supplying the tool
wire to the machining site, the more the feed rate more will be the MRR and rougher
the surface will get.

The effect of gap voltage is also significant. The gap voltage shows the reverse effect
on MRR but shows increasing values against the surface roughness. This is because the
gap voltage is the value which shows the gap voltage intensity generated. The more will
be the value of gap voltage more will be surface roughness. The wire wear also increases
with increase in the gap voltage.

More precise results can be achieved further with the usage of genetic algorithm.

51
 CHAPTER 8
FUTURE SCOPE

The study of tool wear is not much explored, the studies have been started for wire wear
in detail. The best method to find the wire wear is by measuring the diameter of the wire
when it is mounted on the machine with common wire tension and with using advance
measuring machines which can measure the wire on board.

The studies can also be done by using high resolution microscope for measuring every
wire specimen so to find the wire wear with very less amount of error.

The detailed study of tool wear can save lot of money for any production company as
well as it will bring new horizons in the non-traditional machining field.

52
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