Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses
Abstract
:1. Introduction
2. Materials and Methods
2.1. Grey Relational Generating
2.2. Grey Relational Coefficient (GC)
2.3. Grey Relational Grade
3. Results
3.1. Analysis of Variance for SR, CS, and KW
3.2. Analysis of the Effect of Control Factors on Responses
3.2.1. Effect of Current
3.2.2. Effect of Voltage
3.2.3. Effect of Drum Speed
3.2.4. Effect of Nozzle Offset Distance
3.3. Multiresponse Optimization through GRA
Confirmatory Test
4. Conclusions
- Analysis of variance revealed that the voltage, drum speed, and nozzle offset distance were significant factors for surface roughness. However, voltage was the major contributing factor, with a percentage contribution of 45%, followed by drum speed (25.8%) and nozzle offset distance (~21%). Higher values of NOD and V at a low DS yielded a high surface finish.
- Cutting speed during WEDM of SS 304 was mainly influenced by the current, which had an exceptionally high percentage contribution of 85.5%. Moreover, an increase in the current value had a positive impact on the cutting rate. The role of drum speed and nozzle offset distance was observed to be insignificant for cutting rate; however, smaller NOD and larger DS values improved the cutting rate.
- In addition to current and voltage, drum speed was also found to be a contributing factor in reference to kerf width. The percentage contributions of current, voltage, and drum speed were 53.3%, 22.2%, and 21.2%, respectively, for kerf width. However, high values of drum speed and voltage along with a low amount of current yielded a narrower kerf.
- SEM analysis revealed that the cut surface was crowded with spherical modules at a larger nozzle offset distance because the flushing capability of the dielectric had been reduced. A low offset distance value ensured appropriate flushing because of the higher dielectric pressure, which ultimately minimized spherical module formation on the machined surface.
- Against conflicting response attributes such as surface roughness, cutting speed, and kerf width, the optimal combination of WEDM parameters achieved though grey relational analysis was voltage of 50 V, drum speed of 35 Hz, current of 3 A, and nozzle offset distance of 220 mm. This combination provided the maximum cutting speed (2.62 mm/min) along with the minimum amount of surface roughness (4.47 µm) and kerf width (0.32 mm). The results were validated by a confirmatory test, as presented in Table 5 and Figure 11.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Elements | C | Cr | Si | Ni | S | P | Fe |
---|---|---|---|---|---|---|---|
Weight (%) | 0.075 | 18.4 | 1.03 | 9.76 | 0.03 | 0.048 | Balance |
Input Parameters | Units | Levels | |||
---|---|---|---|---|---|
1 | 2 | 3 | 4 | ||
Voltage (V) | V | 50 | 60 | 70 | 80 |
Drum Speed (DS) | Hz | 35 | 40 | 45 | 50 |
Current (I) | amp | 1 | 2 | 3 | 4 |
Nozzle Offset Distance (NOD) | mm | 200 | 220 | 240 | 260 |
ANOVA for SR | |||||||
Source | DF | Seq SS | Adj SS | Adj MS | F | P | % Contribution |
V | 3 | 2.22887 | 2.22887 | 0.74296 | 25.69 | 0.012 | 45 |
DS | 3 | 1.27454 | 1.27454 | 0.42485 | 14.69 | 0.024 | 26 |
I | 3 | 0.32664 | 0.32664 | 0.10888 | 3.77 | 0.153 | 7 |
NOD | 3 | 1.02303 | 1.02303 | 0.34104 | 11.79 | 0.036 | 20 |
Error | 3 | 0.08675 | 0.08675 | 0.02892 | 2 | ||
Total | 15 | 4.93983 | |||||
S = 0.170050 | R − Sq = 98.24% | R − Sq (adj) = 91.22% | |||||
ANOVA for CS | |||||||
Source | DF | Seq SS | Adj SS | Adj MS | F | P | % Contribution |
V | 3 | 0.28033 | 0.28033 | 0.09344 | 3.56 | 0.163 | 6 |
DS | 3 | 0.27686 | 0.27686 | 0.09229 | 3.51 | 0.165 | 6 |
I | 3 | 4.10536 | 4.10536 | 1.36845 | 52.08 | 0.004 | 85 |
NOD | 3 | 0.05902 | 0.05902 | 0.01967 | 0.75 | 0.591 | 2 |
Error | 3 | 0.07883 | 0.07883 | 0.02628 | 1 | ||
Total | 15 | 4.80039 | |||||
S = 0.162098 | R − Sq = 98.36% | R − Sq (adj) = 91.79% | |||||
ANOVA for KW | |||||||
Source | DF | Seq SS | Adj SS | Adj MS | F | P | % Contribution |
I | 3 | 0.01624 | 0.01624 | 0.00541 | 108.19 | 0.001 | 53 |
NOD | 3 | 0.00090 | 0.00090 | 0.00030 | 6.06 | 0.087 | 3 |
V | 3 | 0.00671 | 0.00671 | 0.00224 | 44.71 | 0.004 | 22 |
DS | 3 | 0.00647 | 0.00647 | 0.00216 | 43.14 | 0.006 | 21 |
Error | 3 | 0.00015 | 0.00015 | 0.00005 | 1 | ||
Total | 15 | 0.03047 | |||||
S = 0.007073 | R − Sq = 99.51% | R − Sq (adj) = 86.00% |
Exp No. | Grey Relational Generating | Grey Relational Coefficient | GRA Grade | Ranking | ||||
---|---|---|---|---|---|---|---|---|
SR | KW | CS | SR | KW | CS | |||
1 | 0.0000 | 0.7980 | 0.1965 | 0.3300 | 0.7120 | 0.3835 | 0.4751 | 14 |
2 | 0.2940 | 0.5710 | 0.5648 | 0.4140 | 0.5380 | 0.4696 | 0.4738 | 15 |
3 | 0.3880 | 0.4280 | 0.6796 | 0.4490 | 0.4660 | 0.6095 | 0.5081 | 11 |
4 | 0.6700 | 1.0000 | 0.7536 | 0.6020 | 1.0000 | 0.6699 | 0.7572 | 2 |
5 | 0.6260 | 0.3700 | 0.6250 | 0.5720 | 0.4270 | 0.4820 | 0.4936 | 12 |
6 | 1.0000 | 0.0840 | 0.0194 | 1.0000 | 0.3530 | 0.3377 | 0.5635 | 8 |
7 | 0.6090 | 0.4410 | 0.7702 | 0.5610 | 0.4720 | 0.6851 | 0.5726 | 7 |
8 | 0.5180 | 0.4610 | 0.6140 | 0.5090 | 0.4810 | 0.7799 | 0.5899 | 6 |
9 | 0.4170 | 0.6880 | 0.8640 | 0.4610 | 0.6000 | 0.7862 | 0.6157 | 3 |
10 | 0.4710 | 0.3830 | 0.8113 | 0.4850 | 0.4490 | 0.7260 | 0.5533 | 10 |
11 | 0.4700 | 0.4740 | 0.2552 | 0.4850 | 0.4870 | 0.4017 | 0.4579 | 16 |
12 | 0.3820 | 0.7920 | 0.7400 | 0.4470 | 0.7060 | 0.6579 | 0.6036 | 4 |
13 | 0.1530 | 0.0000 | 0.8477 | 0.3710 | 0.3300 | 0.7665 | 0.4891 | 13 |
14 | 0.7530 | 0.7660 | 1.0000 | 0.6690 | 0.6810 | 1.0000 | 0.7833 | 1 |
15 | 0.7410 | 0.7460 | 0.4271 | 0.6580 | 0.6630 | 0.4859 | 0.6022 | 5 |
16 | 0.7150 | 0.7920 | 0.0000 | 0.6360 | 0.7060 | 0.3330 | 0.5583 | 9 |
Sr. No. | Input Parameter’s Setting | Parameter’s Level | Level Values | Cutting Speed (mm/min) | Kerf Width (mm) | Surface Roughness (µm) |
---|---|---|---|---|---|---|
1 | Optimal Settings | V 1, DS 1, I 3, NOD 2 | V = 50 V, DS = 35 Hz, I = 3 A, NOD = 220 mm | 2.62 | 0.322 | 4.47 |
2 | Nonoptimal Settings | V 3, DS 1, I 3, NOD 3 | V = 70 V, DS = 35 Hz, I = 3 A, NOD = 240 mm | 2.02 | 0.374 | 5.69 |
Percentage Improvement | 29% | 16% | 27.3% |
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Ishfaq, K.; Ahmad, N.; Jawad, M.; Ali, M.A.; M. Al-Ahmari, A. Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses. Materials 2019, 12, 1940. https://doi.org/10.3390/ma12121940
Ishfaq K, Ahmad N, Jawad M, Ali MA, M. Al-Ahmari A. Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses. Materials. 2019; 12(12):1940. https://doi.org/10.3390/ma12121940
Chicago/Turabian StyleIshfaq, Kashif, Naveed Ahmad, Muhammad Jawad, Muhammad Asad Ali, and Abdulrahman M. Al-Ahmari. 2019. "Evaluating Material’s Interaction in Wire Electrical Discharge Machining of Stainless Steel (304) for Simultaneous Optimization of Conflicting Responses" Materials 12, no. 12: 1940. https://doi.org/10.3390/ma12121940