Modelling and optimisation of travelling wire electro-chemical spark machining process

Basanta Kumar Bhuyan and Vinod Yadava

International Journal of Industrial and Systems Engineering, 2014, vol. 18, issue 2, 139-158

Abstract: This paper presents modelling and optimisation of cut quality during a self developed travelling wire electro-chemical spark machining (TW-ECSM) process. In the present study, four input process parameters such as applied voltage, electrolyte concentration, wire feed velocity and workpiece thickness and two output parameters such as surface roughness (R_a) and material removal rate (MRR) are considered. The hybrid approach comprising of Taguchi methodology (TM) and response surface methodology (RSM) is used for modelling whereas multi-objective optimisation is performed using hybrid approach of TM and grey relational analysis (GRA) coupled with entropy measurement methodology. The approach first uses the Taguchi quality loss function to find the optimum level of input parameters. This optimum input parameter values are further used as the central values in the RSM to develop the second-order response model. The entropy measurement methodology is employed for the calculation of weight corresponding to each quality characteristic. The results have been observed that in comparison to TM, the hybrid approach enhances MRR by 117% and reduces the R_a by 10%.

Keywords: travelling wire electrochemical spark machining; TW-ECSM; Taguchi methods; response surface methodology; RSM; grey relational analysis; GRA; entropy measurement methodology; wire ECM; electrochemical machining; modelling; optimisation; applied voltage; electrolyte concentration; wire feed rate; workpiece thickness; surface roughness; surface quality; material removal rate; MRR. (search for similar items in EconPapers)
Date: 2014
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