Application of a Hybrid Approach Using PCA based TOPSIS Method for Multi Objective Optimization of EDM Process Parameters During Machining of H11 Die Steel Using P/M Processed Metal Matrix Composite

  • Authors

    • N. Pallavi Senapati
    • S. Tripathy
    2018-12-13
    https://doi.org/10.14419/ijet.v7i4.39.27726
  • Electric Discharge Machining, Metal matrix composite, PCA, Powder Metallurgy, Taguchi, TOPSIS

  • Abstract

    Metal matrix composites (MMC) are found to have many applications in the space and aviation industries. This paper presents the details of a comparative study made on the machinability of H11 die steel by electric discharge machining (EDM) process using copper and powder metallurgy (P/M) processed Cu-Cr MMC as the tool.  Taguchi method was used for the experimental design and experiments were conducted using L9 orthogonal array for each tool. The present work investigates the influence of machining parameters such as peak current (Ip), pulse on time (Ton), duty cycle (DC) and gap voltage (Vg) on material removal rate (MRR), tool wear rate (TWR), diametral overcut (DOC) and surface roughness (SR). Cu-Cr composite tool demonstrates better performance than copper tool.  Multi-objective optimization was performed using a combination of principal component analysis (PCA) with technique for order of preference by similarity to ideal solution (TOPSIS) to achieve the optimum parameter setting for copper and Cu-Cr tool. The optimal results obtained for copper tool was at Ip=3A, Ton=150µs, DC=80%, Vg=40V and for Cu-Cr tool was at Ip=3A, Ton=200µs, DC=90%, Vg=50V.

     

     

  • References

    1. [1] Ahmad A R, Asokan I, Aravindan S, Electric Discharge Machining of Hybrid Al-SiC-B4C and Al-SiC-Glass MMCs, International Journal of Advance Manufacturing Technology (2010), 49,871-877

      [2] Batish Ajay, Bhattacharya Anirban, Singla V. K., and Singh Gurmail, Study of Material Transfer Mechanism in Die Steels Using Powder Mixed Electric Discharge Machining, Materials and Manufacturing Processes, 2012, 27: 449–456

      [3] Norasetthekul S., Eubank P.T., Bradley W.L., Bozkurt B., Stucker S., Use of zirconium diboride–copper as an electrode in plasma applications, J. Mater. Sci. 34 (1999) 1261–1270.

      [4] Singh S., Maheshwari S., Pandey P.C., Some investigations into the electric discharge machining of hardened tool steel using different electrode materials, J. Mater. Process. Technol. 149 (2004) 272–277.

      [5] Chen W., Cutting forces and surface finish when machining medium hardness steel using CBN tools. Int. j. of Machine Tools Manufacture, 2000, 40, p.455-466

      [6] Qian, L., Robiul Hossan, M. Effect on cutting force in turning hardened tool steels with cubic boron nitride in-serts. -J. of Materials Processing Technology, 2007, 191, p.274-278.

      [7] Fnides B., Aouici H., Yalles M. A., Cutting forces and surface roughness in hard turning of hot work steel X38CrMoV5-1 using mixed ceramic.- Mechanika. -Kaunas: Technologija, 2008, No.2(70), p.73-78.

      [8] Tsai H.C., Yan B.H., Huang F.Y., EDM performance of Cr/Cu-based composite electrodes, Int. J. Mach. Tools Manuf. 43 (2003) 245–252.

      [9] Samuel M.P., Philip P.K., Powder metallurgical tool electrodes for electrical discharge machining, Int. J. Mach. Tools Manuf. 37 (1997) 1625– 1633.

      [10] Marafona J., Wykes C., A new method of optimizing material removal rate using EDM with copper–tungsten electrodes, Int. J. Mach. Tools Manuf. 40 (2000) 153–164.

      [11] Shunmugam M.S., Philip P.K., Improvement of wear resistance by EDM with tungsten carbide P/M electrode, Wear 171 (1994) 1–5.

      [12] Gill Amoljit S, Kumar Sanjeev, Surface Roughness Evaluation for EDM of En31with Cu-Cr-Ni Powder Metallurgy Tool, International Journal of Mechanical, Aerospace, Industrial and Mechatronics Engineering, 2014, Vol:8, No:7

      [13] Mathew Nibu, Kumar Dinesh, Beri Naveen, Kumar Anil, Study of material removal rate of different tool materials during EDM of H11 steel at reverse polarity, International Journal of Advanced Engineering Technology, 2014, E-ISSN 0976-3945

      [14] Singh Baljinder, Singh Paramjit, Tejpal Gaurav, Singh Gurtej, An experimental study of surface roughness of H11 steel in EDM process using copper tool electrode, International Journal of Advanced Engineering Technology, 2012, E-ISSN 0976-3945

      [15] Senapati N. Pallavi, Tripathy S., Samantaray S., A Multi-Objective Optimization using a combined approach of Principal Component Analysis and TOPSIS during Electric Discharge Machining of H11 die steel using P/M processed Cu-Cr-Ni metal matrix composite, International Conference on Electrical, Electronics, and Optimization Techniques (2016)

      [16] Puhan Debaprasanna,, Mahapatra Siba Sankar, Sahu Jambeswar, Das Layatitdev, A hybrid approach for multi-response optimization of non-conventional machining on AlSiCp MMC, Measurement 46, 2013, 3581–3592

  • Downloads

  • How to Cite

    Pallavi Senapati, N., & Tripathy, S. (2018). Application of a Hybrid Approach Using PCA based TOPSIS Method for Multi Objective Optimization of EDM Process Parameters During Machining of H11 Die Steel Using P/M Processed Metal Matrix Composite. International Journal of Engineering & Technology, 7(4.39), 901-906. https://doi.org/10.14419/ijet.v7i4.39.27726

    Received date: 2019-02-21

    Accepted date: 2019-02-21

    Published date: 2018-12-13