Optimization of WEDM process of pure titanium with multiple performance characteristics using Taguchi’s DOE approach and utility concept

doi:10.1007/s11465-013-0256-8

Front Mech Eng

2013, Vol. 8

Issue (2) : 201-214 https://doi.org/10.1007/s11465-013-0256-8

RESEARCH ARTICLE

Optimization of WEDM process of pure titanium with multiple performance characteristics using Taguchi’s DOE approach and utility concept

Rupesh CHALISGAONKAR¹(

), Jatinder KUMAR²

1. Krishna Institute of Engineering and Technology, Ghaziabad-Meerut Highway (NH-58), Ghaziabad, Uttar-Pradesh-201206, India; 2. Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, Haryana-136119, India

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Abstract

This paper describes the development of multi response optimization technique using utility method to predict and select the optimal setting of machining parameters in wire electro-discharge machining (WEDM) process. The experimental studies in WEDM process were conducted under varying experimental conditions of process parameters, such as pulse on time(T_on), pulse off time(T_off), peak current (IP), wire feed (WF), wire tension (WT) and servo voltage (SV) using pure titanium as work material. Experiments were planned using Taguchi’s L27 orthogonal array. Multi response optimization was performed for both cutting speed (CS) and surface roughness (SR) using utility concept to find out the optimal process parameter setting. The level of significance of the machining parameters for their effect on the CS and SR was determined by using analysis of variance (ANOVA). Finally, confirmation experiment was performed to validate the effectiveness of the proposed optimal condition.

Keywords wire electro-discharge machining (WEDM) Taguchi method analysis of variance (ANOVA) utility concept cutting speed (CS) surface roughness (SR)

Corresponding Author(s): CHALISGAONKAR Rupesh,Email:rupesh_chalisgaonkar2000@yahoo.com

Issue Date: 05 June 2013

Cite this article:

Jatinder KUMAR,Rupesh CHALISGAONKAR. Optimization of WEDM process of pure titanium with multiple performance characteristics using Taguchi’s DOE approach and utility concept[J]. Front Mech Eng, 2013, 8(2): 201-214.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-013-0256-8
https://academic.hep.com.cn/fme/EN/Y2013/V8/I2/201

Fig.1 Schematic diagram of WEDM

Fig.2 Ishikawa cause and effect diagram

Fig.3 Modified linear graph for L27 array

Fig.4 Electronica Sprintcut Model (Electra- Elplus 40A DLX) CNC WEDM

Fig.5 Workpiece geometry

Fig.6 Mitutoyo surface roughness tester

Tab.1 Process parameters with their values at three levels

Tab.2 Chemical composition of pure Ti

Tab.3 L27 orthogonal array with parameters and interactions assigned to columns

Tab.4 Experimental data of cutting speed and surface roughness

Fig.7 Mean effect plot for means of cutting speed

Fig.8 Mean effect plot for means of surface roughness

Fig.9 Main effect plot for S/N ratio of cutting speed considering “larger is better”

Fig.10 Main effect plot for S/N ratio of surface roughness considering “smaller is better”

Fig.11 Main effect plot for means of multiple response data considering “larger is better”

Fig.12 Main effect plot for S/N ratios of multiple response data considering “larger is better”

Tab.5 Multiple responses data

Fig.13 Pie chart of factor % contribution for cutting speed (ANOVA raw data)

Tab.6 Analysis of variance for CS (mm/min) raw data, using adjusted SS for tests.

Fig.14 Pie chart of factor % contribution for surface roughness (ANOVA raw data)

Tab.7 Analysis of variance for SR (μm) raw data, using adjusted SS for tests.

Tab.8 Confirmatory experimental results (Multi response optimization)

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