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Commenced in January 2007 Frequency: Monthly Edition: International Publications Count: 29912

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Development of Regression Equation for Surface Finish and Analysis of Surface Integrity in EDM
Electrical discharge machining (EDM) is a relatively modern machining process having distinct advantages over other machining processes and can machine Ti-alloys effectively. The present study emphasizes the features of the development of regression equation based on response surface methodology (RSM) for correlating the interactive and higher-order influences of machining parameters on surface finish of Titanium alloy Ti-6Al-4V. The process parameters selected in this study are discharge current, pulse on time, pulse off time and servo voltage. Machining has been accomplished using negative polarity of Graphite electrode. Analysis of variance is employed to ascertain the adequacy of the developed regression model. Experiments based on central composite of response surface method are carried out. Scanning electron microscopy (SEM) analysis was performed to investigate the surface topography of the EDMed job. The results evidence that the proposed regression equation can predict the surface roughness effectively. The lower ampere and short pulse on time yield better surface finish.
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[1] A. Hascalik and U. Caydas, "Electrical discharge machining of titanium alloy (Ti–6Al–4V),” Appl. Surf. Sci. vol 253, pp. 9007–9016, 2007.
[2] P. Fonda, Z. Wang, K. Yamazaki and Y. Akutsu, "A fundamental study on Ti–6Al–4V’s thermal and electrical properties and their relation to EDM productivity,” J. Mater. Process. Technol. vol 202, pp. 583–589, 2008.
[3] M.A.R. Khan, M.M. Rahman, K. Kadirgama, M.A. Maleque and R.A. Bakar, "Artificial intelligence model to predict surface roughness of Ti-15-3 alloy in EDM process,” World Acad. Sci. Eng. Technol., vol 74, pp. 121–125, 2011.
[4] M. Rahman, Z.G. Wang and Y.S. Wong, "A review on high-speed machining of titanium alloys,” JSME Int. J. Ser. C Mech. Syst. Mach. Elem. Manuf. vol 49(1), pp. 11–20, 2006.
[5] M.M. Rahman, M.A.R. Khan, K. Kadirgama, M.A. Maleque and R.A. Bakar, "Parametric optimization in EDM of Ti-6Al-4V using copper tungsten electrode and positive polarity: A statistical approach,” Math. Methods Tech. Eng. Environ. Sci., pp. 23–29, 2011a.
[6] M.M. Rahman, M.A.R. Khan, K. Kadirgama, M.M. Noor and R.A. Bakar, "Modeling of material removal on machining of Ti-6Al-4V through EDM using copper tungsten electrode and positive polarity,” Int. J. Mech. Mater. Eng. vol 1(3), pp. 135–140, 2010.
[7] S. Prabhu and B.K. Vinayagam, "Effect of graphite electrode material on EDM of AISI D2 tool steel with multiwall carbon nanotube using regression analysis,” Int. J. Eng. Stud. vol 1(2), pp. 93–104, 2009.
[8] K.H. Ho and S.T. Newman, "State of the art electrical discharge machining (EDM),” Int. J. Mach. Tools Manuf. vol 43, pp. 1287–1300, 2003.
[9] K. Ponappa, S. Aravindan, P.V. Rao, J. Ramkumar and M. Gupta, "The effect of process parameters on machining of magnesium nano alumina composites through EDM,” Int. J. Adv. Manufac. Technol., vol 46, pp. 1035–1042, 2010.
[10] B.H. Yan, H.C. Tsai and F.Y. Huang, "The effect in EDM of a dielectric of a urea solution in water on modifying the surface of titanium,” Int. J. Mach. Tools Manuf. vol 45, pp. 194–200, 2005.
[11] M.M. Rahman, M.A.R. Khan, K. Kadirgama and R.A. Bakar, "Prediction of material removal rate for Ti-5Al-2.5Sn in EDM using multilayered perceptron neural network technique,” Recent researches in neural networks, fuzzy systems, evolutionary computing and automation, pp. 17–23, 2011b.
[12] C.L. Lin, J.L. Lin and T.C. Ko, "Optimisation of the EDM process based on the orthogonal array with fuzzy logic and grey relational analysis method,” Int. J. Adv. Manuf. Technol. vol 19, pp. 271–277, 2002.
[13] S.S. Habib, "Study of the parameters in electrical discharge machining through response surface methodology approach,” Appl. Math. Model. vol 33, pp. 4397–4407, 2009.
[14] S.H. Tomadi, M.A. Hassan, Z. Hamedon, R. Daud and A.G. Khalid, "Analysis of the influence of EDM parameters on surface quality, material removal rate and electrode wear of tungsten carbide,” in Proc. the Int. Multi Conf. Engineers and Comput. Scientists, Hong Kong, 2009, pp. 1803–1808.
[15] M.K. Pradhan and C.K. Biswas, "Modelling of machining parameters for MRR in EDM using response surface methodology,” National Conf. on Mechanism Sci. and Technol. From Theory to Appl., Hamirpur, 2008, pp. 535–542.
[16] J. Kumar, J.S. Khamba and S.K. Mohapatra, "An investigation into the machining characteristics of titanium using ultrasonic machining,” Int. J. Machining Machinabiliy Mater. vol 3(1/2), pp. 143-161, 2008.
[17] M.R. Shabgard and R.M. Shotorbani, "Mathematical Modeling of Machining Parameters in Electrical Discharge Machining of FW4 Welded Steel,” World Acad. Sci. Eng. Technol. vol 52, pp. 403-409, 2009.
[18] K.T. Chiang, "Modeling and analysis of the effects of machining parameters on the performance characteristics in the EDM process of Al2O3+TiC mixed ceramic,” Int. J. Adv. Manuf. Technol., vol 37, pp. 523–533, 2008.
[19] D. Mandal, S.K. Pal and P. Saha, "Modeling of electrical discharge machining process using back propagation neural network and multi-objective optimization using non-dominating sorting genetic algorithm-II,” J. Mater. Process. Technol. vol 186, pp. 154–162, 2007.
[20] I. Puertas and C.J. Luis, "A study on the machining parameters optimisation of electrical discharge machining,” J. Mater. Process. Technol. vol 143–144, pp. 521–526. 2003.
[21] M.M. Rahman, M.A.R. Khan, K. Kadirgama, M.M. Noor and R.A. Bakar, "Experimental investigation into electrical discharge machining of stainless steel 304,” J. Appl. Sci. vol 11(3), pp. 549–554, 2011.
[22] K.L. Wu, B.H. Yan, F.Y. Huang and S.C. Chen, "Improvement of surface finish on SKD steel using electro-discharge machining with aluminum and surfactant added dielectric,” Int. J. Mach. Tools Manuf. vol 45, pp. 1195–1201, 2005.
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