Parametric Optimization of Graphite Plate by WEDM

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 07 | July -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 3143
Parametric Optimization of Graphite Plate by WEDM
TOMPE S.V.1, N.A. RAWBAWALE2
1PG Student, Department of Mechanical Engineering, College of Engineering Ambajogai
Maharashtra, India
2Associate Professor, Department of Mechanical Engineering, College of Engineering Ambajogai
Maharashtra, India
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Abstract - Wire electrical discharge machining is an
emerging technology in the area of machiningtoverycomplex
micro products. WEDM is a completely complex technique
regarding the distinct method. Experimentalinvestigationhas
been carried out in multi process micro EDM machine. WEDM
technique is a highly complex, time varying & stochastic
system, which is used in the fields of dies, moulds, precision
manufacturing and contour cuttingetc. Itisespeciallyused for
the aerospace and medical industries. The complex shape can
be generated with high degree of accuracy and surface finish
using CNC WEDM. Hence suitable selection of input variable
for the WEDM process depends heavily on the operator’s
technology & experience. The literature survey has revealed
that a little research has been conducted to obtaintheoptimal
levels of machining parameters to machine on graphite
material. The objective of optimization is to attain the
minimum surface roughness and maximum material removal
rate. In this present study the work piece of graphite plate is
used. The Brass wire of 0.25mm diameter is used as a tool and
distilled water is used as dielectric. The experimentation was
planned as per Taguchi’s L9 Orthogonal array for machining
of graphite material. For each experiment surface roughness
and MRR is determined by using contact type surface coder
and display screen of machine directly.
Key Words: WEDM,MRR,SR,RA,TON,TOFF
1.INTRODUCTION
The Wire electrical discharge machining is one of the
important non-traditional machining processes. There are
various materials having high hardness that can be easily
machined by generating sparks at every few microseconds.
There is sparking mechanism which generates the spark
between wire electrode and work piece, where the
temperature reaches to about 12,000°C. The dielectric fluid
acts as medium for passing of spark current from electrode
to the work piece. Typically the gap between wire and work
piece for WEDM varies from 0.025 to0.05mmandthisgapis
constantly monitored by a computercontrolledsystem.Now
days the numerical control is mainly used according to the
customer requirement for machining. It is widelyusedinthe
aerospace and automotiveindustries.However,theselection
of cutting parameters for obtaining higher cutting efficiency
or accuracy in wire EDM is still not widelyfocused,even with
the most up-to date CNC WEDM machine. The main aim to
optimize the process parameteristoovercomeirregularities
and to achieve the surface roughness and metal removal
rate.
Fig -1: Schematic diagram of WEDM
2. LITERATURE REVIEW
Ashish Srivastava et al [1] have studied on composite
material of Al2024. They selected three levels of each
parameters like current, pulse on time and strengthening
proportion on surface finish and MRR. The response surface
methodology (RSM) process was applied to optimize the
machining parameters for minimum surface roughness and
most MRR. It was determined that surface roughness
increase in peak current and pulse on time.
Neeraj Sharma et al [2] have highlighted in nursing
improvement of eight management factors on MRR, surface
roughness and the width of cut made by saw (kerfs) in
WEDM technique for steel D2. It has been found that pulse
on-time is the foremost vital parameter on roughness, kerfs
and material removal rate.
P.K. Jain and N.K. Jain [3] have studied the impact of
parameters on cutting speed and dimensional deviation for
WEDM exploitation High-strength low-alloy steel. Response
surface methodology was utilized to optimize the strategy
parameter. It was seen that the foremost distinguishedissue
for cutting speed, pulse-on time.

M. Dura raj and N. Swaminathan [4] optimize the strategy
parameters throughout machining of SiCp/6061 Al metal
matrix composite (MMC). They have selected Four input
technique parameters of WEDM namely servo voltage (V),
pulse-on time (TON), pulse-off time (TOFF) and wire feed
rate (WF). highlight of ANOVA results that the voltage and
wire feed rate are very vital parameters and pulse-off time
could be a least vital.
Chengmao zhang et al [5] have Investigation on stainless-
steel (SS304).They use brass wire of 0.25mm diameter as
conductor. It was a levels that optimized input parameter
from result show that minimum surface roughness square
measure 40V gap voltage, 2mm/min wire feed, six
microsecond (μs) pulse on time, 10 μs pulse off time and
equally optimized conditions to urge the minimum kerfs
breadth square measure 50V gap voltage, 2mm/min Wire
Feed, four μs pulse on time, six μs pulse off time.
M. Ghasemi Babbly et al [6] have Highlighted the
investigation on Tin/Si3N4 ceramic, the dependence of
surface texture, surface roughness, and materials removal
rate square measure take into consideration as output
parameter. From this paper it was finished that the material
removal rate increase and pulse off time shows a finish
lower material removal rate.
P. Venkata Ramaiah et al [7] The influence of machining
parameters on surface roughness (SR)andmaterial removal
rate (MRR) of high strength armour steel. It wasconcentrate
the Results show that pulse-on time, pulse-off time, and
spark voltage square measure were vital variables to MRR
and surface roughness.
Yongfeng Guo1 et al [8] Taguchi technique was applied to
experimental results of (WEDM) on Inconel 825. The
Taguchi technique is most ideal and applicable for the
constant improvement of the wire cut EDM technique, once
exploitation of the multiple performance characteristicslike
MRR, surface roughness, and spark gap, for machining the
Inconel 825.
L. Karunamoorthyb et al [9] have investigated gap voltage,
capacitance, feed rate, and wire tension on metal alloy (Ti-
6AL-4V). Analysis of variance (ANOVA) was performed to
identify the numerous factors. From this paper it was show
that maximum MRR and minimum surface roughness need
to be the input parameters are gap voltage (113 V),
capacitance (0.26 μF), feed rate (9 μm/s), and wire tension
Gm. Highlighted the WEDM applications in many areas like
metal 718 by CNC WEDM process.
3 EXPERIMENTAL DETAILS
A WEDM machine, developedbyITRI(Industrial Technology
Research Institute) and CHMER companyTaiwan,isused for
the experiment. In the Brass wire with graphite Work-piece
specimens having thickness 6 mm and square pieces of 10
mm a side were cut by WEDM. Specification of WEDM the
work material, specification of electrode and the other
machining conditions were taken as follows:
Fig -2: WEDM Machine
Table -1: Specification of WEDM
work piece (anode) Graphite Plate
electrode (cathode) 00.25 mm brass wire
Dielectric fluid Distilled water
X,Y axis mm 400×300
U,V,Z TRAVEL 60×60×220
maximum size of work piece
(W×D×H)mm
720×600×215
Motor AC servo motor
wire dia. mm 0.15- 0.3
Max. wire feed 300
wire tension (gm) 300-2500
According to the Taguchi design method L9 Orthogonal
array was chosen for the optimization of the process.
Four control factors were chosen at three levels-
I. Current, Pulse on time, Pulse off time , Wire Tension.
Two response parameters were measured.
I Surface Roughness and MRR
Input process parameters and their levels are given below.
Table -2: WEDM process parameters and their levels
Process Parameter Units Level
Current A 5,10,15
Ton µs 3,5,7
T off µs 20,25,30
Wire tension GM 8,10,12

3.1 Design of Experiment:
Orthogonal arrays are special standard experimental design
that requires only small number of experimental trials to
find the main factor an effect on output.
Table -3: L9 array table for DOE based on Taguchi method
No. of runs Current(a) T on T off Wire Tension
1 5 3 20 8
2 5 5 25 10
3 5 7 30 12
4 10 3 20 12
5 10 5 25 10
6 10 7 30 8
7 15 3 20 8
8 15 5 25 12
9 15 7 30 10
4 EXPERIMENTATION
Fig -3: The cutting of graphite plate by WEDM
Table -4: Measurement of Response
5. METHODOLOGY
Wire EDM Machining and Response Surface Methodology
(RSM) are used to describe the effect of parameters on
graphite Material.
Response Surface Methodology (RSM)
Response Surface Methodology is the combination of
mathematical and statistical technique, used to develop the
mathematical model for analysis and optimization. The
major steps in Response Surface Methodology are:
1. Identification of predominate factors whichinfluencesthe
surface roughness.
2. Developing the experimental design matrix, conducting
the experiments as per the above design matrix.
3. Developing the mathematical model.
4. Determination of constant coefficients of the developed
model.
5. Testing the significance of the coefficients.
6. Adequacy test for the developed model by using analysis
of variance (ANNOVA).
7. Analyzing the effect of input machining parameters on
output response surface roughness and MRR.
6 Result and Discussion
Following mean Signal/Noise ratio graphs are obtained for
different process parameters using MINITAB software.
Fig -4: Graph of Main effect plot for Machining Speed
The second graph indicated the effect of pulse on time on
Machining Speed its decreases and again increases. When
pulse on time from the graph 4, we get the optimumvalue by
selecting highest S/N ratio.
Sr.No. Current Ton
T
off
wire
tension
MRR
Surface
roughness
1 5 3 20 8 5.475 0.194
2 5 5 25 10 6.78 0.148
3 5 7 30 12 7.183 0.107
4 10 3 20 12 9.794 0.140
5 10 5 25 10 7.966 0.153
6 10 7 30 8 4.853 0.191
7 15 3 20 8 6.381 0.149
8 15 5 25 12 7.246 0.187
9 15 7 30 10 7.335 0.122

Fig -5: Main effects plots for data mean
Also from Fig. 5, we get the behavior of Input
parameter on Machining speed.
1) From graph, it is clearly shown that with increase in
current, Machining. When current increases from5to10 μs,
Machining Speed decreases and again increases.
2) Again increases from 5to 7 μs then machining speed
further increases. It is clearly shown that with increase in
pulse off time, material removal rate decreases.
3) The third graph shows the effect of pulse off time on
machining speed when pulse off time increases from 20 to
25 μs, machining speed increases. When pulse off timeagain
increases from 25 to 30 μs then machining speed further
decreases.
4) The fourth graph indicates the effect of wire tension on
machining speed. It is also observed that if wire tension
increases from 8 to 10 Gms then Machining speed increases
now, if wire tension further increases from 10 to 12 Gms
then also there is decrease in Machining speed.
5) From the graph and signal to noise ratio optimum
parameter calculated as below:
Table -5: Standard parameters
Current(A) Ton T off WT
MRR 5 5 25 10
SR(μm) 5 7 30 12
REFERENCES
[1] Ashish Srivastava Amit Rai Dixit , Sandeep Tiwari,“
Experimental Matrix Composite Al2024/SiC” International
Journal of Advance. Research and Innovation Volume 2 , pp
511-515, 2014.
[2] Neeraj Sharma, Rajesh Khanna, Rahuldev Gupta,“Multi
Quality Characteristics Of WEDM Process Parameters With
RSM” Procedia Engineering 64 pp .710 – 719, 2013
[3] Pragya Shandilya, P. k. Jain, N.K. Jain, “ Parametric
Optimization during WEDM response surface methodology”
Procedia Engineering 38(2012),pp. 2371-2377
[4] Chengmao Zhang, “Effect of wire electrical discharge
machining (WEDM) parameters on surface integrity of
nanocomposite ceramics” Ceramics International40
pp.9657–9662 , 2014
[5] R. Bagherian Azhiri & R. Teimouri & M. Ghasemi Baboly
&Z. Leseman , “Application of Taguchi, ANFIS and grey
relational analysis for studying, modeling and optimization
of wire EDM process while using gaseous media” Int J Adv
Manuf Technol,71:279–295,2014.
[6] Ravindranadh Bobbili, V. Madhu, and A. K Gogia, “Effect
of Wire EDM Machining Parameters on Surface Roughness
and Material Removal Rate of High Strength Armor Steel”
Materials and Manufacturing Processes, 28: 364–368,
2013.
[7 ] G. Rajyalakshmi & P. Venkata Ramaiah, “Multiple
process parameter optimization of wire electrical discharge
machining on Inconel 825 using Taguchi grey relational
analysis” Int J Adv Manuf Technology 69:1249–1262,2013.
[8] Pengju Hou “Influence of open-circuit voltage on high-
speed wire electrical discharge machining of insulating
Zirconia
Int J Adv Manuf Technol ,73:229–239,2014
[9] Ibrahem Maher and Ahmed A. D. Sarhan, “Review of
improvements in wire electrode properties for longer
working time and utilization in wire EDM machining” Int J
Adv Manuf Technol 2014.
[10] R. Ramakrishnan, L. Karunamoorthy, “Modeling and
multi-response optimization of Inconel 718on machining of
CNC WEDM process.” journal of materials processing
technology 2 0 7 ( 2 0 0 8 ) pp 343–349.

Parametric Optimization of Graphite Plate by WEDM

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