Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE)

V. N. Gaitonde, M. Manjaiah, S. Maradi, S. R. Karnik, P. M. Petkar, J. Paulo Davim

Research output: Chapter in Book/Report/Conference proceedingChapter

Abstract

HCHCr steel is widely used in cold forming molds, press tools, and die making industries, primarily due to excellent wear resistance, high compressive strength, greater dimensional stability, and high hardness. Due to poor machinability and surface integrity, HCHCr is considered as a difficult to cut material and hence there is a need to study the machinability characteristics. The current chapter deals with the study on wire electric discharge machining (WEDM) characteristics of HCHCr steel using brass electrode. The quadratic models of WEDM characteristics, namely, surface roughness, material removal rate, and tool wear rate were developed in terms of pulse on time, pulse off time, and wire feed using response surface methodology (RSM). The minimum number of experiments was planned as per orthogonal array. The constructed models were statistically tested through analysis of variance and were found to be adequate at 95% confidence interval. The established mathematical models were later employed with differential evolution (DE) to optimize the machining parameters. DE program provides the minimum values of surface roughness and the tool wear rate as well as the maximum material removal rate and the corresponding best combination of pulse on time and wire feed for a given pulse off time. The higher roughness was observed for the surface machined at higher pulse on time, higher pulse off time with higher wire feed rate. The XRD analysis clearly indicates the formation of ferrous oxide and cementite on the machined surface.

Original languageEnglish
Title of host publicationComputational Methods and Production Engineering
Subtitle of host publicationResearch and Development
PublisherElsevier Inc.
Pages199-221
Number of pages23
ISBN (Electronic)9780857094827
ISBN (Print)9780857094810
DOIs
Publication statusPublished - 01-01-2017

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Machining
Response surface methodology
Steel
Differential evolution
Tool wear
Surface roughness
Experiment
Roughness
Mathematical model
Industry
Integrity
Dimensional stability
Wear resistance
Orthogonal array
Compressive strength
Analysis of variance
Confidence interval

All Science Journal Classification (ASJC) codes

  • Economics, Econometrics and Finance(all)
  • Business, Management and Accounting(all)

Cite this

Gaitonde, V. N., Manjaiah, M., Maradi, S., Karnik, S. R., Petkar, P. M., & Davim, J. P. (2017). Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE). In Computational Methods and Production Engineering: Research and Development (pp. 199-221). Elsevier Inc.. https://doi.org/10.1016/B978-0-85709-481-0.00007-0
Gaitonde, V. N. ; Manjaiah, M. ; Maradi, S. ; Karnik, S. R. ; Petkar, P. M. ; Davim, J. Paulo. / Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE). Computational Methods and Production Engineering: Research and Development. Elsevier Inc., 2017. pp. 199-221
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Gaitonde, VN, Manjaiah, M, Maradi, S, Karnik, SR, Petkar, PM & Davim, JP 2017, Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE). in Computational Methods and Production Engineering: Research and Development. Elsevier Inc., pp. 199-221. https://doi.org/10.1016/B978-0-85709-481-0.00007-0

Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE). / Gaitonde, V. N.; Manjaiah, M.; Maradi, S.; Karnik, S. R.; Petkar, P. M.; Davim, J. Paulo.

Computational Methods and Production Engineering: Research and Development. Elsevier Inc., 2017. p. 199-221.

Research output: Chapter in Book/Report/Conference proceedingChapter

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T1 - Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE)

AU - Gaitonde, V. N.

AU - Manjaiah, M.

AU - Maradi, S.

AU - Karnik, S. R.

AU - Petkar, P. M.

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AB - HCHCr steel is widely used in cold forming molds, press tools, and die making industries, primarily due to excellent wear resistance, high compressive strength, greater dimensional stability, and high hardness. Due to poor machinability and surface integrity, HCHCr is considered as a difficult to cut material and hence there is a need to study the machinability characteristics. The current chapter deals with the study on wire electric discharge machining (WEDM) characteristics of HCHCr steel using brass electrode. The quadratic models of WEDM characteristics, namely, surface roughness, material removal rate, and tool wear rate were developed in terms of pulse on time, pulse off time, and wire feed using response surface methodology (RSM). The minimum number of experiments was planned as per orthogonal array. The constructed models were statistically tested through analysis of variance and were found to be adequate at 95% confidence interval. The established mathematical models were later employed with differential evolution (DE) to optimize the machining parameters. DE program provides the minimum values of surface roughness and the tool wear rate as well as the maximum material removal rate and the corresponding best combination of pulse on time and wire feed for a given pulse off time. The higher roughness was observed for the surface machined at higher pulse on time, higher pulse off time with higher wire feed rate. The XRD analysis clearly indicates the formation of ferrous oxide and cementite on the machined surface.

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M3 - Chapter

SN - 9780857094810

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EP - 221

BT - Computational Methods and Production Engineering

PB - Elsevier Inc.

ER -

Gaitonde VN, Manjaiah M, Maradi S, Karnik SR, Petkar PM, Davim JP. Multiresponse optimization in wire electric discharge machining (WEDM) of HCHCr steel by integrating response surface methodology (RSM) with differential evolution (DE). In Computational Methods and Production Engineering: Research and Development. Elsevier Inc. 2017. p. 199-221 https://doi.org/10.1016/B978-0-85709-481-0.00007-0