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Article

Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study

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Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Tamilnadu 600062, India
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Mechanical Engineering, Sri Sivasubramaniya Nadar College of Engineering, Tamilnadu 603110, India
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Key Laboratory of High-efficiency and Clean Mechanical Manufacture, National Demonstration Center for Experimental Mechanical Engineering Education, School of Mechanical Engineering, Shandong University, Jinan 250061, China
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Faculty of Mechanical Engineering, Opole University of Technology, 45-758 Opole, Poland
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Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, 454080 Chelyabinsk, Russia
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Department of Production Engineering, UTP University of Science and Technology, Al. Prof. S. Kaliskiego 7, 85-796 Bydgoszcz, Poland
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Authors to whom correspondence should be addressed.
Academic Editors: Koh-ichi Sugimoto and Henrik Saxen
Metals 2021, 11(7), 1105; https://doi.org/10.3390/met11071105
Received: 19 May 2021 / Revised: 5 July 2021 / Accepted: 9 July 2021 / Published: 11 July 2021
(This article belongs to the Special Issue Optimization and Analysis of Metal Cutting Processes)
In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated through the stir casting process by varying the wt% of reinforcements from 3 to 9. In the machinability studies, the WEDM process control parameters such as gap voltage, pulse-on time, pulse-off time, and wire feed were varied to analyze their effects on machining performance including volume removal rate and surface roughness. The WEDM experiments were planned and conducted through the L27 orthogonal array approach of the Taguchi methodology, and the corresponding volume removal rate and surface roughness were measured. In addition, the multi-parametric ANOVA was performed to examine the statistical significance of the process control parameters on the volume removal rate and surface roughness. Furthermore, the spatial distribution of the parameter values for both the responses were statistically analyzed to confirm the selection of the range of the process control parameters. Finally, the quadratic multiple linear regression models (MLRMs) were formulated based on the correlation between the process control parameters and output responses. The Grass–Hooper Optimization (GHO) algorithm was proposed in this work to identify the optimal process control parameters through the MLRMs, in light of simultaneously maximizing the volume removal rate and minimizing the surface roughness. The effectiveness of the proposed GHO algorithm was tested against the results of the particle swarm optimization and moth-flame optimization algorithms. From the results, it was identified that the GHO algorithm outperformed the others in terms of maximizing volume removal rate and minimizing the surface roughness values. Furthermore, the confirmation experiment was also carried out to validate the optimal combination of process control parameters obtained through the GHO algorithm. View Full-Text
Keywords: hybrid composites; wire electrical discharge machining (WEDM); volume removal rate; surface roughness; Grass–Hooper optimization algorithm hybrid composites; wire electrical discharge machining (WEDM); volume removal rate; surface roughness; Grass–Hooper optimization algorithm
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MDPI and ACS Style

Lenin, N.; Sivakumar, M.; Selvakumar, G.; Rajamani, D.; Sivalingam, V.; Gupta, M.K.; Mikolajczyk, T.; Pimenov, D.Y. Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study. Metals 2021, 11, 1105. https://doi.org/10.3390/met11071105

AMA Style

Lenin N, Sivakumar M, Selvakumar G, Rajamani D, Sivalingam V, Gupta MK, Mikolajczyk T, Pimenov DY. Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study. Metals. 2021; 11(7):1105. https://doi.org/10.3390/met11071105

Chicago/Turabian Style

Lenin, Nagarajan, Mahalingam Sivakumar, Gurusamy Selvakumar, Devaraj Rajamani, Vinothkumar Sivalingam, Munish K. Gupta, Tadeusz Mikolajczyk, and Danil Y. Pimenov. 2021. "Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study" Metals 11, no. 7: 1105. https://doi.org/10.3390/met11071105

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