Abstract The compliance of an integrated approach, principal component analysis （PCA）, coupled with Tagu chi＇s robust theory for simultaneous optimization of cor related multiple responses of wire electrical discha...Abstract The compliance of an integrated approach, principal component analysis （PCA）, coupled with Tagu chi＇s robust theory for simultaneous optimization of cor related multiple responses of wire electrical discharge machining （WEDM） process for machining SiCp rein forced ZC63 metal matrix composites （MMCs） is investi gated in this work. The WEDM is proven better for its efficiency to machine MMCs among others, while the particulate size and volume percentage of SiCp with the composite are the utmost important factors. These improve the mechanical properties enormously, however reduce the machining performance. Hence the WEDM experiments are conducted by varying the particulate size, volume fraction, pulseon time, pulseoff time and wire tension. In the view of quality cut, the most important performance indicators of WEDM as surface roughness （Ra）, metal removal rate （MRR）, wire wear ratio （WWR）, kerf （Kw） and white layer thickness （WLT） are measured as respon ses. PCA is used as multiresponse optimization technique to derive the composite principal component （CPC） which acts as the overall quality index in the process. Consequently, Taguchi＇s S/N ratio analysis is applied to optimize the CPC. The derived optimal process responses are confirmed by the experimental validation tests results. The analysis of vari ance is conducted to find the effects of choosing process variables on the overall quality of the machined component.The practical possibility of the derived optimal process conditions is also presented using SEM.展开更多
There are many advanced tooling approaches in metal cutting to enhance the cutting tool performance for machining hard-to-cut materials. The self propelled rotary tool （SPRT） is one of the novel approaches to improv...There are many advanced tooling approaches in metal cutting to enhance the cutting tool performance for machining hard-to-cut materials. The self propelled rotary tool （SPRT） is one of the novel approaches to improve the cutting tool performance by providing cutting edge in the form of a disk, which rotates about its principal axis and provides a rest period for the cutting edge to cool and allow engaging a fresh cutting edge with the work piece. This paper aimed to present the cutting performance of SPRT while turning hardened EN24 steel and optimize the machining conditions. Surface roughness （Ra） and metal removal rate （rMMR） are considered as machining perfor- mance parameters to evaluate, while the horizontal incli- nation angle of the SPRT, depth of cut, feed rate and spindle speed are considered as process variables. Initially, design of experiments （DOEs） is employed to minimize the number of experiments. For each set of chosen process variables, the machining experiments are conducted on computer numerical control （CNC） lathe to measure the machining responses. Then, the response surface method- ology （RSM） is used to establish quantitative relationships for the output responses in terms of the input variables. Analysis of variance （ANOVA） is used to check the adequacy of the model. The influence of input variables on the output responses is also determined. Consequently, these models are formulated as a multi-response optimi- zation problem to minimize the Ra and maximize the rMMR simultaneously. Non-dominated sorting genetic algorithm-II （NSGA-II） is used to derive the set of Pareto-optimal solutions. The optimal results obtained through the pro- posed methodology are also compared with the results of validation experimental runs and good correlation is found between them.展开更多
Metal matrix composites （MMCs） as advanced materials, while producing the components with high dimensional accuracy and intricate shapes, are more complex and cost effective for machining than conventional alloys. I...Metal matrix composites （MMCs） as advanced materials, while producing the components with high dimensional accuracy and intricate shapes, are more complex and cost effective for machining than conventional alloys. It is due to the presence of discontinuously distributed hard ceramic with the MMCs and involvement of a large number of machining control variables. However, determination of optimal machining conditions helps the process engineer to make the process efficient and effec- tive. In the present investigation a novel hybrid multi-response optimization approach is proposed to derive the economic machining conditions for MMCs. This hybrid approach integrates the concepts of grey relational analysis （GRA）, principal component analysis （PCA） and Taguchi method （TM） to derive the optimal machining conditions. The machining experiments are planned to machine A17075/SiCp MMCs using wire-electrical discharge machining （WEDM） process. SiC particulate size and its weight percentage are explicitly considered here as the process variables along with the WEDM input variables. The derived optimal process responses are confirmed by the experimental validation tests and the results show satisfactory. The practical possibility of the derived optimal machining conditions is also analyzed and presented using scanning electron microscope （SEM） examinations. According to the growing industrial need of making high performance, low cost components, this investigation provides a simple and sequential approach to enhance the WEDM performance while machining MMCs.展开更多
文摘Abstract The compliance of an integrated approach, principal component analysis （PCA）, coupled with Tagu chi＇s robust theory for simultaneous optimization of cor related multiple responses of wire electrical discharge machining （WEDM） process for machining SiCp rein forced ZC63 metal matrix composites （MMCs） is investi gated in this work. The WEDM is proven better for its efficiency to machine MMCs among others, while the particulate size and volume percentage of SiCp with the composite are the utmost important factors. These improve the mechanical properties enormously, however reduce the machining performance. Hence the WEDM experiments are conducted by varying the particulate size, volume fraction, pulseon time, pulseoff time and wire tension. In the view of quality cut, the most important performance indicators of WEDM as surface roughness （Ra）, metal removal rate （MRR）, wire wear ratio （WWR）, kerf （Kw） and white layer thickness （WLT） are measured as respon ses. PCA is used as multiresponse optimization technique to derive the composite principal component （CPC） which acts as the overall quality index in the process. Consequently, Taguchi＇s S/N ratio analysis is applied to optimize the CPC. The derived optimal process responses are confirmed by the experimental validation tests results. The analysis of vari ance is conducted to find the effects of choosing process variables on the overall quality of the machined component.The practical possibility of the derived optimal process conditions is also presented using SEM.
文摘There are many advanced tooling approaches in metal cutting to enhance the cutting tool performance for machining hard-to-cut materials. The self propelled rotary tool （SPRT） is one of the novel approaches to improve the cutting tool performance by providing cutting edge in the form of a disk, which rotates about its principal axis and provides a rest period for the cutting edge to cool and allow engaging a fresh cutting edge with the work piece. This paper aimed to present the cutting performance of SPRT while turning hardened EN24 steel and optimize the machining conditions. Surface roughness （Ra） and metal removal rate （rMMR） are considered as machining perfor- mance parameters to evaluate, while the horizontal incli- nation angle of the SPRT, depth of cut, feed rate and spindle speed are considered as process variables. Initially, design of experiments （DOEs） is employed to minimize the number of experiments. For each set of chosen process variables, the machining experiments are conducted on computer numerical control （CNC） lathe to measure the machining responses. Then, the response surface method- ology （RSM） is used to establish quantitative relationships for the output responses in terms of the input variables. Analysis of variance （ANOVA） is used to check the adequacy of the model. The influence of input variables on the output responses is also determined. Consequently, these models are formulated as a multi-response optimi- zation problem to minimize the Ra and maximize the rMMR simultaneously. Non-dominated sorting genetic algorithm-II （NSGA-II） is used to derive the set of Pareto-optimal solutions. The optimal results obtained through the pro- posed methodology are also compared with the results of validation experimental runs and good correlation is found between them.
文摘Metal matrix composites （MMCs） as advanced materials, while producing the components with high dimensional accuracy and intricate shapes, are more complex and cost effective for machining than conventional alloys. It is due to the presence of discontinuously distributed hard ceramic with the MMCs and involvement of a large number of machining control variables. However, determination of optimal machining conditions helps the process engineer to make the process efficient and effec- tive. In the present investigation a novel hybrid multi-response optimization approach is proposed to derive the economic machining conditions for MMCs. This hybrid approach integrates the concepts of grey relational analysis （GRA）, principal component analysis （PCA） and Taguchi method （TM） to derive the optimal machining conditions. The machining experiments are planned to machine A17075/SiCp MMCs using wire-electrical discharge machining （WEDM） process. SiC particulate size and its weight percentage are explicitly considered here as the process variables along with the WEDM input variables. The derived optimal process responses are confirmed by the experimental validation tests and the results show satisfactory. The practical possibility of the derived optimal machining conditions is also analyzed and presented using scanning electron microscope （SEM） examinations. According to the growing industrial need of making high performance, low cost components, this investigation provides a simple and sequential approach to enhance the WEDM performance while machining MMCs.
