WSEAS Transactions on Applied and Theoretical Mechanics
Print ISSN: 1991-8747, E-ISSN: 2224-3429
Volume 11, 2016
Optimization of Tool Wear Rate During Electrical Discharge Machining of Advanced Materials Using Taguchi Analysis
Authors: ,
Abstract: In electrical discharge machining tool wear is a major problem. The contribution of the tool cost in the total operation cost is approximately 50%. Because of tool wear the geometrical dimensions and form of the tool are not reproduced on the workpiece. Due to these reasons the tool wear has to be carefully handled while planning electrical discharge machining operations. In view of this, present study uses Taguchi’s method to optimize the electrical discharge machining process variables for achieving minimum tool wear rate. NiTi alloy, NiCu alloy and BeCu alloy were consider as the workpiece materials and electrolytic copper was considered as tool electrode. Electrical parameters considered for the study includes gap current, gap voltage, pulse on time and pulse off time along with workpiece electrical conductivity. Experiments were carried out as per the Taguchi’s L18 orthogonal array. The most significant parameter that affects the tool wear rate was obtained by Taguchi’s signals to noise ratio and analysis of variance methods. Based on the statistical analysis it was found that work electrical conductivity, gap current, and pulse on time were the most significant process parameters that affects tool wear rate. The obtained optimal parameter setting provides minimum tool wear rate.
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Keywords: NiTi alloys, NiCu alloys, BeCu alloys, Taguchi approach, Analysis of variance, Tool wear rate
Pages: 46-53
WSEAS Transactions on Applied and Theoretical Mechanics, ISSN / E-ISSN: 1991-8747 / 2224-3429, Volume 11, 2016, Art. #6