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ABSTRACT
Electro Discharge Machining (EDM) is a non-traditional machining route suitable for
difficult-to-cut materials. In this work, machinability aspects of super alloy Inconel 718
have been experimentally investigated during EDM by using Copper tool electrode. Based on
five-factor-five-level L25 Orthogonal Array (OA), experiments have been conducted by
varying the following controllable process parameters viz. OCV (gap voltage), peak current
(IP), Pulse-on Time (Ton), Duty Factor () and Flushing Pressure (Fp). Machining performance
has been evaluated in terms of multiple responses such as Roughness average Ra (of the
EDMed surface), Surface Crack Density (SCD) and White Layer Thickness (WLT).
Aforesaid response functions have been assumed to correspond to Lower-is-Better (LB)
requirement. In view of the fact that traditional Taguchi method alone is incapable to solve
multi-response optimization problem; TOPSIS (Technique for Order Preference by Similarity
to Ideal Solution) has been attempted herein to convert multiple responses into an aggregated
performance index (called closeness coefficient) which has been optimized finally by the
Taguchi method. Additionally, micro-graphic studies have been carried out to analyse various
surface irregularities of EDMed Inconel 718 end product.
1. INTRODUCTION
Technological advances have led to an extensive usage of high strength, high hardness
materials in manufacturing industries. In course of machining of difficult-to-cut materials,
conventional manufacturing processes are increasingly being replaced by the advanced
techniques such as Electro-Discharge Machining (EDM), Ultrasonic Machining (USM),
Electro-Chemical Machining (ECM) and laser machining. EDM has found widespread
application in MEMS (Micro-Electro-Mechanical Systems); tool and die, automobile and
aerospace industries. Therefore, promoting the quality of the EDMed product and thereby
achieving satisfactory machining performance; a thorough understanding of the relationship
between the EDM parameters and the machined surface integrity has become a major
research agenda today (Lee and Tai 2003). EDM is an electro-thermal machining process,
where electrical energy is used to generate electrical spark and material removal mainly
occurs due to thermal energy of the spark. It has become an excellent option to machine
difficult-to-cut materials and high temperature resistant alloys; super alloy Inconel 718, in
the present case.
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
Literature depicts that considerable volume of work has been carried out towards
understanding of machining and machinability aspects of Inconel 718 through EDM,
WEDM, micro-machining etc. Studies on parametric influence and aspects multi-response
optimization have also been attempted. However, it has been observed that majority of the
studies focused on optimization of MRR and surface roughness only. Limited papers have
been found to incorporate surface crack density and white layer thickness as objective
functions aiming to minimize them simultaneously.
Motivated by this the present investigation attempts to determine an optimal setting of
process parameters including OCV (gap voltage), peak current, pulse-on time, duty factor and
flushing pressure on the output characteristics of EDMed Inconel 718 product in terms of Ra,
SCD and WLT. TOPSIS has been used to convert multiple responses into an equivalent
single objective function (closeness coefficient, in the present case) which has been
optimized finally by the Taguchi method.
3. EXPERIMENTAL DETAILS
Inconel 718 plates of dimension 50 50 5 have been used as work material. The chemical
composition (Wt %) of Inconel 718 is [Ni-50.55, Mo-2.8-3.3, Ti-0.65-1.15, C-0.08, Si-0.35,
Cu-0.3, Cr-17-21, Co-1.0, Nb (+Ta)-4.75-5.5, Al-0.2-0.8, Mn-0.35, B-0.006]. A pure copper
rod of circular cross section 20 has been used as tool electrode (Figure 1). The
experiments have been carried out on die sinking EDM setup (Model: Electronica
ElektraPlusPS 50ZNC, Country of manufacture: India). Commercially available EDM oil
with specific gravity of 0.763 has been used as dielectric fluid. Polarity has been kept positive
(i.e. workpiece positive). In the present work, five controllable process variables (parameters)
have been selected based on literature survey. The selected process parameters have been
open circuit voltage (OCV) (also called gap voltage), peak current (Ip), pulse-on time (Ton),
duty factor () and flushing pressure (Fp). Each process parameter has been varied at five
discrete levels (refer Table 1) as per configuration of parametric setting (domain of variation)
available with the setup.
The design of experiment has been selected based on 5-level-5-factor L25 Orthogonal Array
(OA) shown in Table 2. Experiments have been conducted as per 25 factorial settings. Both
workpiece and tool have been immersed in dielectric fluid. The machining duration has been
kept constant (10 minutes) for each experimental run. The responses studied have been
Roughness average (Ra) of the machined surface, Surface Crack Density (SCD) and White
Layer Thickness (WLT) obtained on the top surface of EDMed Inconel 718. The snap of
EDMed workpiece has also been shown in Figure 2.
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
3.2 Surface Crack Density (SCD): To measure the surface crack density, the top surface
morphology of the EDMed surface has been studied using Scanning Electron Microscopy
(SEM) (Model: Joel JSM-6480LV, Country: Japan) at magnification of 500. For a
particular sample, SEM images have been captured in three different locations and
corresponding surface crack densities have been collected. The average of these three has
been considered for that particular specimen. For a particular sample area, the total crack
length has been measured using PDF-X Change Viewer Software. The total crack length
divided by the specimen area provides the measure of SCD.
3.3 White Layer Thickness (WLT): The spark occurring during an EDM operation melts
and vaporizes a small area on the workpiece surface. At the end of the pulse-on time, a small
amount of molten material is ejected from the surface and the remaining melted liquid re-
solidifies. This re-solidified/recast layer is typically very fine grained and hard, and may be
alloyed with carbon from the cracked dielectric or with material transferred from the tool. It
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
is also called the white layer since it remains unaffected by etching, and it appears white in
colour under the optical microscope (Tomlinson and Adkin 1992). In this study, the image of
white layer has then been viewed under SEM (Model: Joel JSM-6480LV, Country: Japan)
with a magnification of 1000. The thickness of the white layer has been measured by
ImageJ Software at five different locations across each cross-sectioned specimen and an
average value has been considered for further analysis.
4. METHODOLOGY
4.1 TOPSIS Method
TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) method was firstly
proposed by (Hwang and Yoon 1981). The basic concept of this method is that the chosen
alternative (the most appropriate alternative) should have the shortest distance from the
positive ideal solution and the farthest distance from negative ideal solution. Positive ideal
solution is a solution that maximizes the benefit criteria and minimizes adverse (cost) criteria;
whereas, the negative ideal solution maximizes the benefit criteria (Higher-is-Better; HB) and
minimizes the adverse criteria (Lower-is-Better; LB). The steps involved for calculating the
closeness coefficient values in TOPSIS are as follows:
Step 1: This step involves the development of initial decision making matrix. The row of this
matrix is allocated to one alternative and each column to one attribute. The decision making
matrix can be expressed as:
A1 x11 x12 xij x1n
A2 x21 x22 x2 j x2 n
D
Ai xi1 xi1 xij xin
(1)
Am xm1 xm 2 xmj xmn
Here, Ai ( i 1,2...,25) represents possible alternatives; C j 1,2...3; represents the criteria
(responses) relating to alternative performance. xij is the criterion value of Ai with respect
to criteria C j . Here, m 25, n 3.
Step 2: Obtain the normalized decision matrix rij . This can be represented as:
xij
rij
m
i 1
xij2
(2)
Here, rij represents the normalized criterion value of Ai with respect to C j .
Step 3: Obtain the weighted normalized decision matrix. Here, V vij can be found as:
vij w j rij (3)
Here, j 1 w j 1
n
Step 4: Determine the positive ideal (best) and the negative ideal (worst) solutions in this
step. The positive ideal and negative ideal solution can be expressed as:
(a) The positive ideal solution
A (max v j J ), (min v j J i 1,2...., m)
i
ij ij
i
v1 , v2 ,..., v j ,..., vn (4)
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
v , v2 ,..., v
1 j ,..., vn
(5)
Here
J j 1,2,...., n j, associated with benefit criteria; and,
J j 1,2,...., n j, associated with adverse (cost) criteria.
Step 5: Determine the distance measures. The separation measures of each alternative from
the positive ideal solution and the negative ideal solution are given by n - dimensional
Euclidean distance from the following equations:
n
S i (v
j 1
ij v j ) 2 , i 1,2,..., m , (6)
n
Si (v
j 1
ij v j ) 2 , i 1,2,..., m, (7)
Step 6: Calculate the relative closeness (also called closeness coefficient) with respect to the
ideal solution:
S (8)
Ci i , i 1,2,..., m; 0 Ci 1.
Si Si
Step 7: The alternative with corresponds to the highest Ci value is considered to be the most
appropriate choice.
In the present study closeness coefficient Ci has been optimized (maximized) by Taguchi
method to obtain optimal setting of process parameters for desired output features in relation
to EDM of Inconel 718.
6. CONCLUSIONS
This paper presents an integrated optimization philosophy using TOPSIS concept
combined with Taguchi method for multi-response optimization in the context of EDM
on Inconel 718. An optimal setting of process parameters (including gap voltage, peak
current, pulse-on-time, duty factor and flashing pressure) has been determined to improve
machining performances in terms of Ra, SCD and WLT. Due to the inability of Taguchi
method to solve multi-response optimization problem, the proposed TOPSIS approach
looks helpful in aggregating multiple response features into an equivalent single index
(i.e. C i in the present case) which has been optimized finally by Taguchi method
Mean response tables (mean S/N ratio of C i ) indicate that peak current (IP) is the most
significant parameter to influence overall machining performance.
The optimal process parameter setting appears as (A4B1C1D5E3) i.e. OCV=80V, IP=3A,
Ton=100s, =85% and FP=0.4 bar.
SEM images of EDMed surfaces of Inconel 718 have also been investigated. It has been
concluded that by proper modification of process parameters surface defects,
irregularities, formation of cracks, formation of white layer etc. can be substantially
reduced.
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
Table 3. Computed separation measures, closeness coefficient and corresponding S/N ratio
Distance Distance
measure from measure from Closeness Corresponding Predicted S/N
Sl. No. Positive Ideal Negative Ideal Coefficient S/N Ratio Ratio
solution solution [dB] [dB]
S i S i C i
1 0.0513 0.0620 0.5472 -5.2366
2 0.0654 0.0385 0.3707 -8.6187
3 0.0781 0.0247 0.2399 -12.3991
4 0.0805 0.0265 0.2480 -12.1112
5 0.0641 0.0354 0.3561 -8.9684
6 0.0492 0.0631 0.5619 -5.0063
7 0.0497 0.0586 0.5411 -5.3340
8 0.0707 0.0293 0.2928 -10.6685
9 0.0704 0.0292 0.2930 -10.6619
10 0.0684 0.0645 0.4851 -6.2838
11 0.0644 0.0677 0.5128 -5.8016
12 0.0605 0.0459 0.4311 -7.3077
13 0.0718 0.0300 0.2946 -10.6155 -0.093894
14 0.0618 0.0488 0.4412 -7.1082
15 0.0772 0.0314 0.2893 -10.7718
16 0.0584 0.0569 0.4934 -6.1352
17 0.0557 0.0498 0.4717 -6.5275
18 0.0525 0.0489 0.4820 -6.3386
19 0.0355 0.0662 0.6512 -3.7253
20 0.0756 0.0384 0.3368 -9.4520
21 0.0473 0.0777 0.6216 -4.1305
22 0.0430 0.0566 0.5683 -4.9090
23 0.0607 0.0387 0.3893 -8.1938
24 0.0714 0.0365 0.3380 -9.4207
25 0.0783 0.0427 0.3531 -9.0425
Figure 5. Surface crack on EDMed Inconel 718 obtained at (A4B2C5D3E1) i.e. Vg=80V,
IP=5A, Ton=500s, =75% and FP=0.2 bar
Figure 6. White layer thickness (WLT) on EDMed Inconel 718 obtained at (A4B2C5D3E1) i.e.
Vg=80V, IP=5A, Ton=500s, =75% and FP=0.2 bar
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
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