EDM

Study of EDM and Optimization of its machining parameters
Historical Perspective
In 1770, English physicist Joseph Priestley studied the erosive effect of electrical discharges. Furthering Priestley's research, the EDM process was invented by two Russian scientists, Dr. B. R. Lazarenko and Dr. N. I. Lazarenko, in 1943. In their efforts to exploit the destructive effects of an electrical discharge, they developed a controlled process for machining of metals. Their initial process used a spark machining process, named after the succession of sparks (electrical discharges) that took place between two electrical conductors immersed in a dielectric fluid. The discharge generator effect used by this machine, known as the Lazarenko circuit, was used for many years in the construction of generators for electrical discharge. Additional researchers entered the field and contributed many fundamental characteristics of the machining method we know today. In 1952, the manufacturer Charmilles created the first machine using the spark machining process and was presented for the first time at the European Machine Tool Exhibition in 1955. In 1969 Agie launched the world's first numerically controlled wire-cut EDM machine. Seibu developed the first CNC wire EDM machine 1972 and the first system manufactured in Japan. There is clearly a need to understand the process closely. When Japan began its reconstruction efforts after world war2, it faced an acute shortage of good quality of raw materials, high quality manufacturing equipment and skilled engineers. The challenge was to produce high quality products and continue to improve the quality under those circumstances. The task of developing a methodology to meet the challenge was assigned to Dr. Genichi Taguchi, who at that time was a manager in Nippon Telephone & Telegraph Company. Thorough his research in the 1950s and early 1960s Dr. Taguchi developed the foundations of robust design and validated its basic philosophies by applying them in the development of many products. In recognition of this contribution, he received the individual Deming Award in 1962, which is one of the highest recognition in quality field. The robust design method can be applied a wide variety of problems. The application of the method in electronics, automotive products, photography, and many others industries have been an important factor in the rapid industrial growth and the subsequent domination of international market in these industries by Japan.
Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Introduction
Electric discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). Material is removed from the work piece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, or simply the tool or electrode, while the other is called the work piece-electrode, or work piece. When the distance between the two electrodes is reduced, the intensity of the electric field in the volume between the electrodes becomes greater than the strength of the dielectric (at least in some point(s)), which breaks, allowing current to flow between the two electrodes. This phenomenon is the same as the breakdown of a capacitor (condenser) (see also breakdown voltage). As a result, material is removed from both the electrodes. Once the current flow stops (or it is stopped depending on the type of generator), new liquid dielectric is usually conveyed into the inter-electrode volume enabling the solid particles (debris) to be carried away and the insulating proprieties of the dielectric to be restored. Adding new liquid dielectric in the inter-electrode volume is commonly referred to as flushing. Also, after a current flow, a difference of potential between the two electrodes is restored to what it was before the breakdown, so that a new liquid dielectric breakdown can occur.

Study of Electro Discharge Machining:
Process :
In EDM, a potential difference is applied between the tool and work piece. Both the tool and the work material are to be conductors of electricity. The tool and the work material are immersed in a dielectric medium. Generally kerosene or deionised water is used as the dielectric medium. A gap is maintained between the tool and the work piece. Depending upon the applied potential difference and the gap between the tool and work piece, an electric field would be established. Generally the tool is connected to the negative terminal of the generator and the work piece is connected to positive terminal. As the electric field is established between the tool and the job, the free electrons on the tool are subjected to electrostatic forces. If the work function or the bonding energy of the electrons is less, electrons would be emitted from the tool (assuming it to be connected to the negative terminal). Such emission of electrons are called or termed as cold emission. The cold emitted electrons are then accelerated towards the job through the dielectric medium. As they gain velocity and energy, and start moving towards the job, there would be collisions between the electrons and dielectric molecules. Such collision may result in ionisation of the dielectric molecule depending upon the work function or ionisation energy of the dielectric molecule and the energy of the electron. Thus, as the electrons get accelerated, more positive ions and electrons would get generated due to collisions. This cyclic process would increase the concentration of electrons and ions in the dielectric medium between the tool and the job at the spark gap. The concentration would be so high that the matter existing in that channel could be characterised as plasma. The electrical resistance of such plasma channel would be very less. Thus all of a sudden, a large number of electrons will flow from the tool to the job and ions from the job to the tool. This is called avalanche motion of electrons. Such movement of electrons and ions can be visually seen as a spark. Thus the electrical energy is dissipated as the thermal energy of the spark.

Process Parameters :
The process parameters in EDM are mainly related to the waveform characteristics. Fig. 2 shows a general waveform used in EDM.
The waveform is characterised by the The open circuit voltage - Vo The working voltage - Vw The maximum current - Io The pulse on time the duration for which the voltage pulse is applied - ton The pulse off time - toff The gap between the work piece and the tool spark gap - The polarity straight polarity tool (-ve) The dielectric medium External flushing through the spark gap.

Characteristics of EDM
(a) The process can be used to machine any work material if it is electrically conductive (b) Material removal depends on mainly thermal properties of the work material rather than its strength, hardness etc. (c) In EDM there is a physical tool and geometry of the tool is the positive impression of hole or geometric feature machined. (d) The tool has to be electrically conductive as well. The tool wear once again depends on the thermal properties of the tool material (e) Though the local temperature rise is rather high, still due to very small pulse on time, there is not enough time for the heat to diffuse and thus almost no increase in bulk temperature takes place. Thus the heat affected zone is limited to 2 4 m of the spark crater (f) However rapid heating and cooling and local high temperature leads to urface hardening which may be desirable in some applications (g) Though there is a possibility of taper cut and overcut in EDM, they can be controlled and compensated.
Dielectric:
In EDM, as has been discussed earlier, material removal mainly occurs due to thermal evaporation and melting. As thermal processing is required to be carried out in absence of oxygen so that the process can be controlled and oxidation avoided. Oxidation often leads to poor surface conductivity (electrical) of the workpiece hindering further machining. Hence, dielectric fluid should provide an oxygen free machining environment. Further it should have enough strong dielectric resistance so that it does not breakdown electrically too easily but at the same time ionise when electrons collide with its molecule. Moreover, during sparking it should be thermally resistant as well. Generally kerosene and deionised water is used as dielectric fluid in EDM. Tap water cannot be used as it ionises too early and thus breakdown due to presence of salts as impurities occur. Dielectric medium is generally flushed around the spark zone. It is also applied through the tool to achieve efficient removal of molten material.

Equipment:
Dielectric reservoir, pump and circulation system Power generator and control unit Working tank with work holding device X-y table accommodating the working table The tool holder The servo system to feed the tool
Modelling of Material Removal and Product Quality

Material removal in EDM mainly occurs due to intense localised heating almost by point heat source for a rather small time frame. Such heating leads to melting and crater formation as shown in Fig.
The molten crater can be assumed to be hemispherical in nature with a radius r which forms due to a single pulse or spark. Hence material removal in a single spark can be expressed as
the energy content of a single spark is given as

A part of this spark energy gets lost in heating the dielectric, and rest is distributed between the impinging electrons and ions. Thus the energy available as heat at the workpiece is given by
Now it can be logically assumed that material removal in a single spark would be roportional to the spark energy. Thus
Now material removal rate is the ratio of material removed in a single spark to cycle time. Thus
The model presented above is a very simplified one and linear relationship is not observed in practice. But even then such simplified model captures the complexity of EDM in a very efficient manner. MRR in practice does increase with increase in working voltage, current, pulse on time and decreases with increase in pulse off time. Product quality is a very important characteristic of a manufacturing process along with MRR. The followings are the product quality issues in EDM Surface finish Overcut Tapercut No two sparks take place side by side. They occur completely randomly so that over time one gets uniform average material removal over the whole tool cross section. But for the sake of simplicity, it is assumed that sparks occur side by side as shown in Fig.
Thus it may be noted that surface roughness in EDM would increase with increase in spark energy and surface finish can be improved by decreasing working voltage, working current and pulse on time. In EDM, the spark occurs between the two nearest point on the tool and workpiece. Thus machining may occur on the side surface as well leading to overcut and tapercut as depicted in Fig. 5. Taper cut can be prevented by suitable insulation of the tool. Overcut cannot be prevented as it is inherent to the EDM process. But the tool design can be done in such a way so that same gets compensated.

RC type Relaxation Circuit of EDM:
In RC type generator, the capacitor is charged from a DC source. As long as the voltage in the capacitor is not reaching the breakdown voltage of the dielectric medium under the prevailing machining condition, capacitor would continue to charge. Once the breakdown voltage is reached the capacitor would start discharging and a spark would be established between the tool and work piece leading to machining. Such discharging would continue as long as the spark can be sustained. Once the voltage becomes too low to sustain the spark, the charging of the capacitor would continue. Fig. 8 shows the working of RC type EDM relaxation.
Analytical Results and Formulae:

During charging, at any instant, from circuit theory, Differential equation:
Solution:
where,
Ic = charging current Vo= open circuit voltage Rc= charging resistance C = capacitance Vc= instantaneous capacitor voltage during charging
Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur 9
During discharging, the electrical load coming from the EDM may be assumed a totally resistive and is characterised by a machine resistance of Rm. then the current passing through the EDM machine is given by:
where, Id = discharge current or current flowing through the machine Vc= instantaneous capacitor voltage during discharging Rm= machine resistance
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Study of EDM and Optimization of its machining parameters Study of Taguchis method of Design of experiment using orthogonal arrays:
Literature Survey:
The model quality improvement focuses on the reduction on variability of the manufactured product. It is more costly to costly the cause of variations than to make a process insensitive to control the cause of variations than to make a process insensitive to those variations. The manufacturing variability can never be controlled if checked at the manufacturing and the inspection stages only. Considerable advantages can be obtained by achieving product quality at manufacturing process stage (Design stage) instead of controlling quality at manufacturing process stage or through the inspection of the finished product. Taguchi method is a powerful tool for the design of high quality system. It provides a simple, efficient and systemic approach to optimize design of performance, quality and cost. The methodology is valuable when the design parameters and qualitative or discrete. Taguchi parameter design can optimize the performance characteristics through the setting of design parameters and reduce the sensitivity of the system performance to source of variations. In recent years the rapid growth of interest in the Taguchi method has led to numerous applications of the method in a world-wide range of industries and nations. In the present research work, the above methodology is employed to optimize the machining parameters and to find out the most important factors and their influence on the quality characteristics, i.e. surface roughness. In order to obtain better surface roughness, the proper setting of cutting parameters is crucial before the process takes place. As a starting point for determining cutting parameters, technologists could use the hands on data tables that are furnished in machining data handbooks. Lin (1994) suggested that a trial and error approach could be followed in order to obtain the optimal machining conditions for a particular operation. Consequently, it is a very time consuming process of identifying the optimum cutting conditions for a particular operation. Recently, a Design of Experiment (DOE) has been implemented to select manufacturing process parameters that could result in a better quality product. The DOE is an effective approach to optimize the throughput in various manufacturing related processes. In their study, three independent variables, each with three levels, had total of (33) = 27 experimental runs. Oftentimes, the optimum metal cutting process required studying more than three factors for the cutting parameters. For example, if a DOE setup considered 4 or 5 independent variables, each with at least three levels, then (34)=81 runs or (35)=243 runs were required in the experiments. Imagining the total cost of these experimental runs, one could conclude that it was very costly for the industry. In addition,

the time of these runs could delay any quality resolving action for the industry. More industrial technology (IT) graduates are facing challenges to improve the quality of products and processes with minimum cost and time constraints in their careers. The Taguchi parameter design techniques has been proved to be successful in the meeting this challenge over the past 15 years. Therefore, there is a need to not only introduce our IT graduates to DOE but also Taguchi parameter design. In the present work, the experiments have been designed using highly fractional factorial experimental design (Taguchis orthogonal array) to determine the influence of various factors on the response. The experimental findings are used to identify the best combination of parameters. It has been shown that this method yield the same or even better results (in term of precision) as a complete factorial experiment. Basically the Taguchi methodology is valuable when the design parameters are qualitative and discrete. In recent years, the rapid growth of interest in the Taguchi method has led to numerous applications of the method in a worldwide range of industries and nations. Surface finish is one of the important criteria to be considered for proper functioning of many machined part. It is found from result of metal cutting experiments that machining variables like peak current, Pulse on Time and feed, and tool geometry have a marked influence on the quality of surface produced. The roughness is directly dependent on the peak current. In practice, the machining variables are often adjusted so as to give dimensional accuracy only and further, if the finish is unsatisfactory, the setup is adjusted until this difficulty is eliminated. The objective of this investigation is to experimentally determine the effect of process variables on the surface finish obtainable during the process and also to identify the parameters affecting the surface roughness
Subject overview:
Design of experiments (DOE) is a powerful statistical technique introduced by R.A Fisher in England in 1920s to study the effect of multiple variables simultaneously. In his early applications, fisher wanted to find out how much rain, water, fertilizer, sunshine etc. are needed to produce the best crop. Since that time, much development of the technique has been taken place in the academic environment, but did help generate many applications in the production floor. As a researcher in Electronic Control Laboratory in Japan, Dr. Genechi Taguchi carried out significant research with DOE techniques in the late 1940s he spent considerable effort to make his experimental technique more user friendly (easy to apply) and applied it to improve the quality of manufactured products. Dr. Taguchis standardized version of DOE, popularly known as the Taguchi approach, was introduced in the USA in the early 1980s.

Today it is one of the most effective quality building tools used by engineers in all types of manufacturing activities. The DOE using Taguchi approach can economically satisfy the needs of problem solving and product/process design optimization projects. By learning and applying this technique, engineers, scientists and researchers can significantly reduce the time required for experimental investigations. DOE can be highly effective when we wish to: Optimise product and process design, study the effects of multiple factors (i.e.variables, parameters, ingredients, etc.) on the performance, and solve production problems by objectively laying out the investigate experiments. (Overall application goals). Study influence of individual factors on the performance and determine which factor has more influence, which one have one less. We can also find out which factor should have tighter tolerance and which tolerance should be relaxed. The information from the experiments will tell us how to allocate quality assurance resources based onobjective data. It will indicate whether a suppliers part causes problems or not(ANOVA data), and how to combine different factors in their proper settings to get the best results(Specific Objectives). Further the experimental data will allow us to determine: How to substitute a less expensive part to get the same performance How much money we can save the design improvement we propose How we can determine which factor is causing most variations in the result How we can set up our process such that it is insensitive to the uncontrollable factors Which factors have more influence on the mean performance What we need to do to reduce performance variation around the target How we can adjust the factors for a system whose response varies proportional to signal factor(Dynamic response) How to combine multiple criteria of evaluation into a single index How we can adjust factor for overall satisfaction of criteria of evaluations How the uncontrollable factors affect the performance
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Taguchi Parameter Design:
In the early 1950s, Dr. Genichi Taguchi, The father of quality engineering, introduced the concept of offline quality control techniques known as Taguchi parameter design. Offline quality control techniques are those activities performed during the product (or process) design and development phases. Taguchi parameter design is based on the concept of fractional factorial design. The two major goals of parameter design are: 1. To minimise the process or product variation 2. To design robust and flexible processes or products those are adaptable to environmental conditions. Robust means that the process or product performs consistently and is relatively insensitive to factors that are difficult to control. Two important tools used in parameter design are orthogonal arrays and signal-tonoise(S/N) ratios. Orthogonal arrays have a balanced property in which every factor setting occurs the same number of times for every setting of all other factors in the experiment. Orthogonal arrays allow researchers or designers to study many design parameters which can be obtained with minimum time and resources. The signal-to-noise ratio is simply a quality indicator by which the experimenters and designers can evaluate the effect of changing a particular design parameter on the performance of the process or product. The following are the steps of Taguchi parameter design: 1. 2. 3. 4. 5. 6. 7. Select the quality characteristics Select noise factors and control factors Select orthogonal array Conduct the experiments Analyse results; determine optimum factor level combination Predict optimum performance Confirm experimental design
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Types of Optimization Problems
Taguchi Method treats optimization problems in two categories:
Static Problems
Generally, a process to be optimized has several control factors, which directly decide the target or desired value of the output. Such a problem is called as a Static Problem. This is best explained using a P-Diagram, which is shown (P stands for process or product). Noise is shown to be present in the process but should have no effect on the output! This is the primary aim of the Taguchi experiments-to minimize variations in output even though noise is present in the process. The process is then said to have become ROBUST.
NOISE
P-Diagram
OUTPUT
Fig 3.1 P-Diagram for STATIC Problems
Dynamic Problems
If the product to be optimized has a signal input that directly decides the output, the optimization involves determining the best control factor levels so the input signal/Output ratio is closest to the desired relationship. Such a problem is called as a Dynamic Problem.
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This is best explained by a P-Diagram, which is best shown below. Again the primary aim of the Taguchi experiments-to minimize in output even though noise is present in the process- is achieved by getting improved linearity in the input/output relationship.
NOISE
SIGNAL
P-Diagram
OUTPUT
Fig.3.2 P-Diagram for DYNAMIC problems
8-Steps in Taguchi Methodology

Taguchi method is a scientifically disciplined mechanism for evaluating and implementing improvements in products, processes, materials, equipment, and facilities. These improvements are aimed at improving the desired characteristics and simultaneously reducing the number of defects by studying the key variables controlling the process and optimizing the procedures or design to yield the best results. The method is applicable over a wide range of engineering fields that include processes that manufacture raw materials, sub systems, products for professional and consumer markets.
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8-Steps in Taguchi Methodology are:
Identify the main function, side effects, and failure mode
Identify the noise factors, testing conditions and quality characteristics
Identify the objective function to be optimized
Identify the control factors and their levels
Select the orthogonal array matrix experiment
Conduct the matrix experiment
Analyze the data; predict the optimum levels and performance
Perform the verification experiment and plan the future action
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Taguchi Method and ISO-9000
The ISO-9000 aims at improving the capability of an organization as a whole to manufacture products to specified technical specification and quality standards and to deliver them to the customer on time. Taguchi Method, on the other hand, attacks the product design itself. Through product and process design optimization it improves product quality and reduces costs drastically. Taguchi Method and ISO-9000 thus complement each other.
Quality Engineering Principles
Though Quality can be defined as conformance to specification and fitness for use etc in the general concept, these definitions do not cover the entire implied meaning of quality. The ideal Quality a customer can expect is that the product delivers the target performance each time the product is used, under all intended operating conditions and throughout its intended life, with no harmful side effects.
Dr. Taguchi brought the facility in the fraction defective definition for the quality, in which the number of defectives based on the principle is depicted in Fig. 3.1 was the only concern. As per his theory, the measure of quality of a product is in terms of the total loss to society due to functional variation and harmful side effects. Under ideal quality, this loss is equal to zero. Greater the loss, lower the quality. As per this the total cost of the product is the sum of the operating cost including maintenance and inventory, the manufacturing cost, the R & D cost(the time, laboratory charges, resources etc) and the cost incurred by its breakdown and thereby the losses caused to the society.
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Quality Loss Function & the Fraction Defective Fallacy

As per the definition, the quality loss function is the total loss incurred by the society due to failure of the product to deliver the target performance and due to harmful side effects of the product including its operating cost. According to the primitive concepts of quality, the product was certified as good quality if measured characteristics were within the specification & Vice versa. This is shown in Fig. 3.3
General Trend Of Quality Definition
Reject Good Bad Good
Accept Good Good Good
Reject
Target-
Target
Target +
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This means that all products that meet the specifications are equally good. But in reality it is not so. The product whose response is exactly on target gives the best performance. As the products performance deviate from the target, the quality becomes progressively worse. These two quality philosophies are narrated in Fig. 3.4. as in one case, the focus is on meeting the target and on other case the focus is on meeting tolerance. This is the actual case study result on SONY TV companies of USA & Japan and demonstrates how the japan made TVs were branded as high quality products by following the principle of focussing the target than focussing the tolerance.
From these it can be realized that the true quality measure should not be based on the step function as shown in Fig. 3.3 but as a quadratic loss function as shown in Fig. 3.4. Here the quality loss function L(y) is symmetric about the target performance. As the performance deviate from the target the quality loss correspondingly increases. Also the cost of replacement or repair and represents the acceptable limit.
Quality loss L(y) A
Target-
Target
Target+
Fig. Quality loss as a step function and quadratic function
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As shown in Fig., with the quadratic loss function the quality loss is given by the relation L=K(y-m)^2 , where k is constant called Quality Loss Coefficient. When y=m, loss is zero. The loss L(y) increases slowly in the neighbourhood of m; but as we go further from m, the loss increases more rapidly. The average quality loss incurred by a customer, who receives a product with y as a the quality characteristics will be L(y).
L()y Quality loss
m-
m L=K(Y-m)^2 Fig. Quadratic Quality Loss
m+
L=Loss associated with attribute y m=Specification target k=constant depending upon the cost and width of the species
Example : The cost of scraping a part is Rs. 100 when it deviates 0.50mm from a target nominal of 2 mm. Rs 100=k(2.5-2)^2 K=Rs. 400 per mm^2 L=400(y-2)^2

Different Types of Quality Loss Function
I. Nominal-the best Type
Is applicable where the quality characteristics y has a finite target value, usually non-zero and the Q loss is symmetric on either side of target. E.g color density of a TV set . This type is schematically shown in fig. 3.6
L()y Quality loss
m-
m+
Fig. Quality loss function for Nominal the best type
II.
Smaller the better type

For quality characteristics that can never take negative values and their ideal value will be zero and as their value increases, performance becomes progressively worse.
A
Loss
Fig. Quality Loss for smaller the better type
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Eg. Radiation leakage from a microwave oven , Response time of computer Pollution from
automobile etc.
III.
Larger the better type

For Quality characteristics that do not take negative values and zero is their worst value. As their value becomes larger the performance becomes progressively smaller. Their ideal value is infinity and that point loss=zero. E.g.: Bond Strengthof adhesive.
L(y)=k(1/y^2)
loss
A Fig. 3.8 Quality loss for larger the better type
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Matrix Experiments using Orthogonal Array
Robust design draws on many ideas from statistical experimental design to plan experiments for obtaining dependable information about variables involved in making engineering decisions. Various types of matrices are used for planning experiments to study several decision variables simultaneously. Among them, robust design makes heavy use of the orthogonal arrays. Robust design adds a new dimension to statistical experimental design. It explicitly addresses the following concerns faced by all product & process designers.
How to reduce economically the variation of a product function in the customers environment. (Note that achieving a product function consistently on target maximizes customers satisfaction ) How to ensure that decisions found to be optimum during laboratory experiments will prove to be so in manufacturing & in customer environment.
In addressing these concerns, robust design uses the mathematical formalism of statistical experimental design. A matrix experiment is a set of experiments, where we change the setting of the various parameters we want to study from one experiment to another. After conducting a matrix experiment, the data from all experiments in the set taken together are analyzed to determine the effects of various parameters. The analysis of Means(ANOM) and the analysis of variance (ANOVA) are used to interpret the data to find the sensitivity of each parameters of interest. Conducting the matrix experiments using special matrices called Orthogonal Arrays , allows the effect of several parameters to be determined efficiently and is an important technique in robust design. The different levels of the parameters are known as experimental region or the region of interest. Orthogonality is interpreted in a combinatory sense -(i.e. ) for any pair of columns, all combinations of factor levels occurs and they occur on equal number of times. This is called the balancing property and it implies Orthogonality. So an Orthogonal Array can be defined as a matrix with the columns representing the number of parameters to be studied with their different levels in different combinations of experiments and the number of rows equal to the number of experiments. Standard orthogonal arrays are designed and are available. Selection of an orthogonal array for a robust design project is based on the number of degrees of freedom of the experiment in

such a way that the number of experiments should be greater than or equal to the number of degrees of freedom. Each parameter with n levels will have n-1 degrees of freedom and overall mean will have one degree of freedom. In case of a robust design project with 4 parameters and three levels, the total degrees of freedom will be 9. So the selected standard orthogonal array should have at least 9 rows. A L4 array means an orthogonal array with 4 rows and an L8 array have 8 rows. Some of the standard orthogonal arrays are shown here in Table. Here the otrhogonality is interpreted in a combinatory sense-(i.e.) for any pair of columns all combinations of factor levels occur and they occur on equal number of times. The column y1 to y4 in Table below are the different measurements taken on each setting to capture noise effect. The performance or the responses measured in these matrix experiments are analyzed using ANOM & ANOVA to find the relative effects of noises on the response. By this method the optimum values of the control factors for which the sensitivity of the response to the L9 othogonal array
Column N0.
Trial No. 1 2 3 4 5 6 7 8 9 1 1 1 1 2 2 2 3 3 3 2 1 2 3 1 2 3 1 2 3 3 1 2 3 2 3 1 3 1 2 4 1 2 3 3 1 2 2 3 1
Y1 * * * * * * * * *
y2 * * * * * * * * *
y3 * * * * * * * * *
y4 * * * * * * * * *
Table. L9 Orthogonal array
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As mentioned earlier the columns y1 to y4 corresponds to the response measurements to capture the effects of noises. These measurements should be planned according to the sources of noises in the given problem. For each trial the average of all these y values are to be taken. Typically there are the following two choices regarding noise factors: Improve the quality without controlling or removing the causes of variation to make the product robust against noise factors. Improve the quality by controlling the noise factors , or recommending certain actions to control the noise factors.
The detailed steps in robust design are illustrated below:

L4 Array L8 Array
Expt. No. 1 2 3 4 1 1 1 2 2
Column 2 1 2 1 2 3 1 2 2
Exp No. 1 2 3 4 1 5 6 7 8 2 2 2 2 1 1 2 2 1 1 1 1 1 2 1 1 2 2
Column 3 1 1 2 2 2 2 1 1 4 1 2 1 2 1 2 1 2 5 1 2 1 2 2 1 2 1 6 1 2 2 1 1 2 2 1 7 1 2 2 1 2 1 1 2
Table: L4& L8 orthogonal arrays with two levels.
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Study of EDM and Optimization of its machining parameters Selection of factors levels:
A minimum of two levels is necessary to estimate a factors effect. Continuous factors must be discretised (in preferably equal intervals). Example: Levels of a length parameters: 1 cm, 1.5 cm and 2.0 cm. The more levels the more experimental runs that are necessary/. The number of levels indicates the resolution of effects that can be predicted. The advantage of taking minimum of three points to capture the second order effect is demonstrated in Fig. 4.5 and Fig 4.6 more the number of levels means more the capture of nonlinearity, but more the number of experiments and associated efforts. So it is recommended to consider optimum of three levels. Fig. 4.5 demonstrates how the nonlinearity can be missed if only two levels are taken and in Fig 4.6, it is shown that considering three levels will help in better representation of actual effect, which can be nonlinear. Even a three level combination wouldnt capture the exact relationship. So the entire matrix experimentation may have to be repeated several times to get most robust design.
Factor Assignment:
The selected factors are assigned to the different columns of the specific orthogonal array as shown below. The OA system in Table 4.4 is a 3 level, a 4 four parameter and 9 experiment orthogonal array. The first column represents, starting from 1 to 9. Second to fourth columns are the levels of each parameter or factors A,B,C and D. This will result in 9 experiments with factor combinations as given in each row. For example, the first experiment will be conducted with all the factors A, B, C and D at level 1. For the second experiment factor a will be at level 1 & all other factors at 2 and so on. As per this project concern this chapter introduces the techniques of matrix experiments based on experimental rrays for optimisation of machining parameter to measure surface roughness. The engineering issues inviolved in planning and conducting matrix experiment and the technique of constructing orthogonal array are discussed in the following section
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Trial number 1 2 3 4 5 6 7 8 9
Factor A 1 1 1 2 2 2 3 3 3
Factor B 1 2 3 1 2 3 1 2 3
Factor C 1 2 3 2 3 1 3 1 2
Factor D 1 2 3 3 1 2 2 3 1
Table - factor level assignments

Before starting it is very essential to construct the proper orthogonal array for conducting the experiment in a specific manner.
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Study of EDM and Optimization of its machining parameters Selecting a standard orthogonal Array:
Taguchi has tabulated 18 basic orthogonal arrays that were called standard orthogonal arrays. In many case studies, any of the arrays table 4.5, listed below is available and and can be used directly to plan a matrix experiment. An array name indicates the number of rows and columns it has, and also the number of levels in each of columns. Thus array L4 (23) has four rows and three level column ; and seven t3-level columns. Thus there are eight columns in the L18 (2137). Table 4.5 listed the 18 standard orthogonal arrays along with the number of columns at different levels: Orthogonal No. of array rows L4 L8 L9 L12 L16 L16 L18 L25 L27 L32 L32 L36 L36 L50 L54 L64 L64 L81 4 8 9 12 16 16 18 25 27 32 32 36 36 50 54 64 64 81 Maximum no. of factors 3 7 4 11 15 5 8 6 13 31 10 23 26 12 26 63 21 40 Maximum no. of columns at these levels 2 3 4 5 3 7 11 15 1 31 1 11 3 1 1 63 4 7 13 12 13 25 40 5 9 21 6 11 -
2 LEVEL ARRAYS: L4, L8, L12, L16, L32, L64 3 LEVEL ARRAYS: L9, L27, L81. MIXED 2- AND 3- LEVEL ARRAYS: L18, L36, L36, L54. TABLE -4.5 Standard Orthogonal Arrays
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Example: A case study has only two level factors and we are only interested in main effect
only. Here there are total eight degree of freedom- one of overall mean and seven for the seven 2 level factor. Thus the smallest array L8 has seven 2- level columns and hence this can study perfectly each column of array will have one factor assigned to it.
Counting the degree of freedom:

The first step tin constructing the orthogonal array to fit specific case is to count total degree of freedom that tells the minimum number of experiments that must be performed to study all the chosen control factors. To begin with one degree of freedom is associated with the overall mean regardless the no. of experiments to be conducted. And as we have three 3-level factors, the degree of freedom associated with each factor will be 2 degrees of freedom. As we want to know the response change when the comparisons are done with other two factors. So, the degree of freedom for this project can be calculated as follows.: Source of DOF Three 3level factor Overall mean Total DOF 3*(3-1)=6 1 7
Since there three level factors in this project, it is preferable to use array from the three level series because there are sevan degrees of freedom, the array must have 7 or more rows. Looking at Table 4.5 we see that the smallest array with the smallest array with at least 7 rows is Ls. but this array has seven 2-level columns. As per uor project, we nrrd 3-level column. The next larger array is Ls which has four 3-level columns. Here we can assign three 3-Level factors to three of the four 3-level columns, keeping one 3-level column empty. Keeping one or more column of an array empty lose not lose orthogonality of the matrix experiment. So Ls is a good choice for this experiment. In a situation like this, we would take another look at the control factors if there is an additional control factor to be studied which we may have ignored as less important. If one exist it should assign in the empty column. Doing this allow us a chance to gain information about this additional factor without spending any more resources.
30

Linear graph and interaction assignment
Linear graph
Linear graph represent the interaction information graphically and make it easy to assign and interactions to the various columns of an orthogonal array. In a linear graph dots and lines represent the column of an array. When two dots are connected by a lines, it means that the interaction of the two column represented by the dots is contained in column represented by the line. In a linear graph each dot and each line has distinct column numbers associated with it. Further every column of the array is represented in its linear graph once and only once. One standard linear graph for the array Ls is given in fig 4.7. It has two dots (or nodes) corresponding to columns 1 and 2. Also it has one lines (or edges) representing column 3and 4. This line corresponds to the interaction between column 1 and 2. 1 2 Fig 4.7 Linear graph
in general, linear graph dose not show the interaction between every pair of columns of the orthogonal array. That information contained in the interaction table.
Interaction between factors

Two factors (A and B) consider interaction between them one has influence of of the effect of the other factor respectively. Consider the factors Temperature and Humidity and their influence on comfort level. If the temperature is increased by, say 20 degree F, the comfort level decreased by, say 30% when humidity is kept at 90 %. On a different day, if the temperature is raised the same amount at humidity level of 70%, the comfort level is reported to drop only by 10%. In this case the factors temperature and humidity are interacting with each other. Interaction: Is an effect (output) and does not alter the trial condition. Can be determined even if no column reserved for it. Can be fully analysed by keeping appropriate column empty. Affect the optimum condition and expected result.
31

Interaction table shows in which column the interaction is contained. Thus it can be used to determined which column of the array should be kept empty in order to estimate particular interaction. The L9 orthogonal array has four column and nine rows. As per our project all the factors that are chosen have three levels. So from the four 3-level column, colimn four is designated as empty column and factor A through C were assigned respectively 1,2,3.any columns can be assigned to any factor, exept to the factor that are difficult to change, which should be assigned to the column toward left.
Expt no
Column number and factor assignment 1 A 1 1 1 2 2 2 3 3 3 2 B 1 2 3 1 2 3 1 2 3 3 C 1 2 3 2 3 1 3 1 2 4 E 1 2 3 3 1 2 2 3 1
1 2 3 4 5 6 7 8 9
*empty column are identified by E Table - L9 orthogonal array and Factors assignment
32
The nine rows of the L9 array represent the nine experiment 1 to be conducted at level 1 to for each of the three next chapter. These labels can be read from table 4.6, which is mentioned in next chapter. However to make it convenient and to prevent translation error, the entire matrix of table 4.6 should should be translated using the level definitions in table 4.7 to create the experimenters log sheet.
Expt no
Column number and factor assignment 1 A 8 8 8 10 10 10 12 12 12 2 B 200 500 750 200 500 750 200 500 750 3 C 6 12 18 6 12 18 6 12 18
1 2 3 4 5 6 7 8 9
Table The experimenters log
33
Study of EDM and Optimization of its machining parameters Multi-objective optimization:

Generally in industries for every product and process there are always more than one responses that are of manufacturing and quality interest. While varying the input parameters to change the output the values of responses change and sometimes in a completely independent manner. From the quality point of view it cant be allowed for one response to be of very high quality and other to be of very low. Therefore, the multi optimization problem solving requires finding out a perfect balance between the values of different responses so that the overall quality can be maximized. In modern industry the goal is to manufacture low cost, high quality products in a short time. Furthermore, during the problem solving the experimentation is to be done. For experimentation the input parameters are to be selected to study their effect on responses. The responses chosen to be studied upon should be of quality importance. This implies that the responses selected should be such that the quality depends on them highly. Selection of parameters is whole new task. After the selection of parameters and responses different levels of input parameter are decided. Then the combinations of these parameter levels are made and experiment are conducted. Observations show the variation of response at every different combination of input parameters. After this the multi-response analysis techniques are used to analyse the data and find out the best combination. Here in this study the experiments are planned through the Taguchi method which generally quite successfully implemented in process optimization. Therefore the study intends to apply the Taguchi method to plan the experiments on the EDM operation. After the planning of experiments, the study is to investigate the optimization of EDM operation parameters using the Grey Relational Analysis method to obtain the best combination or optimum parameters to obtain the best multi response i.e. surface finish, tool wear rate, and material removal rate. Here we shall employ statistical methods to EDM operation. There are a lot of different parameters affecting surface finish, tool wear rate, and material removal rate are peak current, applied voltage, pulse on time, pulse off time, dielectric flow rate etc. The surface properties, average roughness, electrode wear rate, and material removal rate (MRR) are selected quality targets or the response variables. The controlling parameters that are chosen for the study purpose are peak current, pulse on time, and duty cycle. An optimal parameter combination of the turning operation will be found out via the Grey Relational Analysis. By analysing the Grey relational matrix, the degree of influence for each controllable factor onto each quality target can also be ascertained.
Study of EDM and Optimization of its machining parameters Grey Relational Analysis :
Grey Relational Analysis. The Grey System Theory that was developed by Deng (1982) is mainly utilized to study system models uncertainty, analyse relations between systems, establish models, and forecast and makes decisions (Deng, 1984). Grey Relational Analysis is utilized to probe the extent of connections between two digits by applying the methodology of departing and scattering measurement to the actual measurement of distance. Grey Relational Analysis is an effective means of analysing the relationship between two series. This study applies grey relational analysis to measure the similarity between the series.
1. Data Pre-processing
Grey data processing must be performed before Grey correlation coefficients can be calculated. A series of various units must be transformed to be dimensionless. Usually, each series is normalized by dividing the data in the original series by their average. Let the original reference sequence and sequence for comparison be represented as xo(k) and xi(k), i=1, 2, . . .,m; k=1,2, . . ., n, respectively, where m is the total number of experiment to be considered, and n is the total number of observation data. Data pre-processing converts the original sequence to a comparable sequence. Several methodologies of pre-processing data can be used in Grey relation analysis, depending on the characteristics of the original sequence.
If the target value of the original sequence is the-larger-the-better, then the original sequence is normalized as follows:
If the purpose is the-smaller-the-better, then the original sequence is normalized as follows:
35

However, if there is a specific target value, then the original sequence is normalized using,
2. Grey Relational Coefficients:. Following the data pre-processing, a Grey relational coefficient can be calculated using the pre-processed sequences. The Grey relational coefficients are calculated to express the relationship between the ideal (best =1) and the actual experimental results. The grey relational coefficient ij can be expressed as follows:
Where xi is the ideal normalized results for the ith performance characteristics and is the distinguishing coefficient which is defined in the range 0 1. is also called environmental factor.
Computing the Grey Relational Grades:

A Grey relational grade is a weighted sum of the Grey Relational Coefficients. The Grey relational grade corresponding to each performance characteristic is to be computed and the overall evaluation of the multi response characteristic is based on the Grey relational grade, which is given by:
GRG =
, Here, the Grey relational grade represents the level of correlation between the reference and comparability sequences. If the two sequences are identical, then the value of the Grey

relational grade equals to one. The Grey relational grade also indicates the degree of influence exerted by the comparability sequence on the reference sequence. Consequently, if a particular comparability sequence is more important to the reference sequence than other comparability sequences, the Grey relational grade for that comparability sequence and the reference sequence will exceed that for other Grey relational grades. The Grey relational analysis is actually a measurement of the absolute value of data difference between the sequences, and can be used to approximate the correlation between the sequences.
37
Study of EDM and Optimization of its machining parameters EXPERIMENTAL DESIGN, SET-UP AND ANALYSYS:
Principle of operation: Electrical discharge machining
In the precision engineering the electrical discharge machining is very important method of manufacturing. In this electrical sparks cause the metal removal and MRR is measured due to heat produced. Work piece and tool both are conductive material. Spark is generated between tool and work piece and thats why the electricity is generated and heat is produced all these happens within micro seconds. The frequency of sparking may be thousands of sparks in a second the area over which he spark is effective is very small. And a very high temperature is developed. Partly melting and partly vaporizing material from a localised area on the both of electrodes i. e. work piece and tool is found. The material is removed in the form of craters which spreads over the entire surface of the work piece. Finally the cavity produced in the work piece is approximately the replica of the tool. To have machined cavity as replica of the tool wear should be zero. The tool wear is minimised by Taguchis method. Fig.
The above figure shows the experimental set-up with basic components of z- axis controlled electrical discharge machine. The schematic diagram of machining operation through electrical discharge machining shown in the fig. The EDM used for our experiment has been manufactured by electronica machine Tools Ltd.
38
Study of EDM and Optimization of its machining parameters Specification of the EDM machine used for experimentation
Value of current density varies with the tool material used. 1. For copper maximum current density is 5 to 7 amp/ cm2. 2. For graphite maximum current density varies from 7 to 10 amp/cm2
3. For Tungsten Copper maximum current density varies from 12 to 15 amp/cm2
Pluse on- time: Range 0.5 to 4000 micro seconds

The following discrete value can be taken with this EDM in the process.
Pulse on time values: 0.5, 0.75, 1.5, 2, 3, 4, 5, 7, 5, 10, 15, 20, 30, 40, 50, 75, 100, 150,
200, 300, 400, 500, 750, 1000, 1500, 2000, 3000, and 4000.
Pulse duty factor: Range 1 to 12 in the steps of 1.
Gap voltage: 50 V Flushing Pressure: 0.1 kg/cm2 Electrode: copper Electrode polarity: positive Dielectric: kerosene (EDM oil) Flushing condition: Side pressure flushing Mains voltage: 3, 415 V Peak current: Range 0 to 50 ampere in steps of 0.5. Surface Roughness Measurement: Sutronic 10.
39
Study of EDM and Optimization of its machining parameters Factors to be optimized:

The most important factor to be optimized is surface roughness since cost and life of a component depends upon its surface roughness. The S/N to be used for surface roughness is smaller the better. The factor of concern is Material removal rate. Higher the material removal rate, higher will be the production. The S/N ratio to be used for MRR is larger the better. To have the exact machined cavity replica of the tool the wear should be as small as possible. Therefore, the S/N ratio for this case will be smaller the better.
Selection of the control factors:

In case of EDM the control factor i.e. the factors which can be easily controlled and affects the response are: Duty cycle Pulse on time Ton Peak current
PULSE ON TIME: During this period the voltage is applied across the tool and the work piece. DUTY CYCLE: it is the ratio of on time and of time of EDM. Duty cycle control the amount of time the pulse should apply the energy. PEAK CURRENT: it is the maximum current obtained in the process.
Selection of the factor levels:

More the numbers of the factor levels mean more the capture of linearity but more the number of experiments and associated effort. Three factor levels are considered optimum in this experiment to reach any conclusion. Duty cycle: Low Medium High 8 10 12 (Range: 1 to 12 in the steps of 1)
40

Current: Low Medium High (Range: 0 to 50 amp in steps of 0.5) 6 Amp 12 Amp 18 Amp
Pulse on time Ton: (Range 0 to 400 s) Low 200 s
Medium 500 s High 750 s
Selection of orthogonal array:

Out of 18 basic tabulated orthogonal arrays to select an appropriate orthogonal array degree of freedom is defined as the no. of comparisons between the design parameter to be made to determine which level is better and specifically by how much. Once the degree of freedom is known, the next step is to select an appropriate orthogonal array. Here the degree of freedom associated with each parameter is two, as the there are three levels and one degree of freedom is associated with mean of the parameters regardless the no. of parameters. Therefore, the degree of freedom is 3*2 + 1= 7. The Taguchis design suggests that: DOF of Orthogonal Array => Total degree of freedom Thus, the orthogonal array that will be satisfying this condition is L 9 array (its degree of freedom is 8). This array has nine rows that represent the trial conditions for the factor levels indicated by the no. of rows. The vertical column corresponds to the factors specified in the study and each contains a total of nine conditions for the factor assigned to that column. Each column has nine conditions (1,1), (1,2), (1,3),(2.1),(2,2), (2,3), (3,1), (3,2), (3,3). Note that any two columns have same no. of combinations. So, all four columns are said to be balanced, orthogonal, and statistically independent of each other. The experimental layout for the orthogonal array is shown in table. Since the orthogonal array has four column it has one column empty for the error of experiment. Orthogonality is not lost by one empty column. The input parameters are put in the column and there outputs are MRR, SR, and TW.

The experiments were performed in similar sequence as mentioned in the table. Data obtained for the response through the experiments were performed in the similar sequence as mentioned in the table. During the experiments the data obtained as response is noted.
ORTHOGONAL ARRAY OF THE FACTORS
S. no.
Duty cycle (T)
Ton(s)
Peak current (Ampere) 6 12 18 12 18 6 18 6 12
E(error)
1. 2. 3. 4. 5. 6. 7. 8. 9.
8 8 8 10 10 10 12 12 12
200 500 750 200 500 750 200 500 750
1 2 3 3 1 2 2 3 1
42

The above sequence when was executed on the machine the following observations were obtained:
Table 1: Tool Wear Rate
S. NO.
Weight in gm. (before machining)
Weight in gm. (after machining)
Difference
1. 2. 3. 4. 5. 6. 7. 8. 9.
160.484 158.625 160.172 160.389 159.345 160.435 158.406 159.981 160.345
160.435 158.406 159.345 159.981 158.017 160.416 157.159 159.951 159.903
0.049 0.219 0.827 0.408 1.328 0.019 1.247 0.03 0.451
43

Table 2: Material Removal Rate S. no. Before machining After machining Weight difference
1. 2. 3. 4. 5. 6. 7. 8. 9.
Weight Avg. surface Weight Avg. surface (gm.) roughness(s) (gm.) roughness(s) 83.628 39.4 82.737 19.1 80.432 83.63 79.119 84.203 84.149 85.184 83.779 89.169 36.7 35.2 31.2 29.8 29.6 31.4 30.7 31.7 76.807 80.665 76.413 80.854 83.531 81.844 82.984 86.326 28.65 28.5 19.125 26.25 15.98 26.00 18.55 24.30
0.891 3.625 3.018 2.706 3.349 0.618 3.34 0.795 2.843
44
S.no. Duty Ton P.I. E cycle 1. 2. 3. 4. 5. 6. 7. 8. 9. 8 8 8 10 10 10 12 12 12 200 500 750 200 500 750 200 500 750 6
Surface roughness 3 17 4 17.9
Avg. S.R. 19.1 28.65 28.5
MRR
TWR
1 2 1 20.7 21.1
74.25 302.08 251.5 225.5
4.08 18.25 68.92 34
12 2 29.6 25.8 28.8 30.4 18 3 2.6 34.3 30.7 26.4
12 3 11.9 20.6 20.3 31.7 19.125 18 1 32.9 22.5 20.8 28.8 6 2 10.9 18 15.3 19.7 26.25 15.8 26 18.55 24.3
279.04 110.06 51.50 1.58
18 2 24.5 23.7 28.5 26.3 6 3 12.7 27.8 25.0 8.7
278.33 103.92 66.25 236.92 2.50 37.58
12 1 34.7 20.9 13.2 28.3
45
Study of EDM and Optimization of its machining parameters ANALYSIS OF RESULTS:

Grey relational analysis of collected data:
Step 1: Normalization of response data: Normalized response table: Formula used:
Where: xi*(k) is the normalized response, and xi(k) is the orignal response
Avg. S.R. 19.1 28.65 28.5 19.125 26.25 15.8 26 18.55 24.3
Normalized Avg. S.R. 0.7537 0.0 0.0118 0.7517 0.1894 1.00 0.20915 0.797 0.3433
MRR
Normalized MRR 0.09 1.00 0.798 0.694 0.908 0.00 0.905 0.0588 0.7399
TWR
Normalized TWR 0.9769
74.25 302.08 251.5 225.5 279.04 51.50 278.33 66.25 236.92
4.08
18.25 0.8463 68.92 0.3792 34 0.701
110.06 0.00 1.58 1
103.92 0.0566 2.50 0.99
37.58 0.668
46
Study of EDM and Optimization of its machining parameters Step 2: Calculation of Grey relational Coefficients (GRC) and Grade (GRD).
Formula used:
(i(k) is GRC)
& GRD=
GRC (Avg. S.R.) 0.6699 0.33 0.3359 0.6681 0.3815 1.00 0.373 0.7112 0.4322
GRC (MRR) 0.3546 1.0 0.7122 0.6203 0.8446 0.3333 0.8403 0.3469 0.6578
GRC (TWR) 0.9608 0.7648 0.4461 0.6258 0.3333 1.000 0.3464 0.9 0.6
GRD 0.6617 0.6994 0.4981 0.6088 0.5198 0.7777 0.52467 0.6793 0.5033
As shown in the table that the greatest value of grey relational grade is .7777 therefore the combination of the parameters in the experiment will have the best possible compromise between the responses and the optimized machining parameters.
47
Regression analysis of the experimental data:

Regression analysis: Surface roughness vs x1, x2, and x3The Regression
analysis was performed by MINITAB software to find out the interaction of Duty cycle (x 1), Pulse on time Ton (x2), and Peak Current (x3) on the average surface roughness (SR), and Material removal rate (MRR). The regression equation obtained is given below: regression equation obtained is given as:
Different values of surface roughness is obtained by keeping two values constant and varying any one of the value. Three lines are plotted in one graph showing change in nature of one factor by varying the other. This shows the interaction one factor with other.
48

1. Effect of Duty cycle on surface roughness with varying pulse on time
Ton=200 Ton=500 Ton=750 S.R.
D.C.
Surface roughness is decreasing with increase in pulse n time. Higher is the duty cycle lower is the surface roughness. However variation in Pulse On Time effects the nature of graph of Duty Cycle. With the increase in Pulse On Time the curve the curve become almost flat i.e, there is very slight change in surface roughness.
49

2. Effect of Duty Cycle on surface roughness with varying peak current
I.P.=6 I.P.=12 I.P.=18
S.R.
D.C.
All the three lines in the graph almost coincide with each other. This shows that peak current feebly affects the nature of graph of duty cycle vs surface roughness. Higher value of surface should be selected to minimize surface roughness.
50

3. Effect of Pulse ON Time on Surface Roughness with varying Peak Current
I.P.=6 I.P.=12 I.P.=18
S.R.
Ton
nature of the graph is changing wiyh varying peak current. It shows that peak current and pulse on time interacts with each other in the manner shown in the graph.
51

4. Effect of pulse on time on Surface Roughness with duty cycle varying
D.C. 8 D.C. 10 D.C. 12
S.R.
Ton
Pulse on time has very less effect on surface roughness at low duty cycle but this effect becomes significant at higher value of duty cycle. Surface roughness starts increasing with pulse on time at higher value of duty cycle.
52

5. Effect of Peak Current on Surface Ruoghness with Duty Cycle
S.R.
D.C. 8 D.C. 10 D.C. 12
I.P.
With the increase in peak current the surface roughness increases. As the lines obtained are parallel it shows that with increase in pulse on time the surface roughness increases but the nature of the graph remains unaffected.
53

6. Effect of Peack Current on Surface Roughness wih varying Pulse on Time
S.R.
Ton 200 s Ton 500 s Ton 750 s
I.P.
Since all the three lines almost coincide with each other, it shows that effect of these two factors on surface roughness are almost independent of each other.
54

Regression analysis MRR vs. x1, x2, x3
Similar as obtained for surface roughness different values of maerial rate is obtained by keeping two values constant and varying any one of the value three lines are plotted in one graph showing change in nature of one factor by varying the other this shows the interaction of one factor with other.
1.
Effect of duty cycle on MRR with varying Pulse on Time
MRR decreases with increase in Duty cycle. With increase in Ton the curve shifts downwards.
55

2.
Effect of duty cycle on mrrr with varying peak current
With increases in duty cycle mrr decreases, but the nature of the curve remains same. It can be seen that the changes are not very high.
3.
Effect of Pulse on Time on MRR with varying Duty Cycle
With increase in TON the MRR decreases. At lower duty cycle the curve is shifted high but as d.c. increases the MRR decreases. At high peak current the MRR increases with increase in duty cycle.
56
4.
Effect of Pulse on time on MRR with varying peak current
With increase in Pulse on Time the MRR decreases. The magnitude of MRR increases but the nature remains same.
5.
Effect of Peak Current on MRR with varying Duty Cycle
MRR increases with increasing Peak current. The nature of the curve remains same .
6.
Effect of peak current on MRR with varying Pulse on Time
MRR increases with increasing peak current. The nature of the curve remains same. With increasing Ton MRR decreases.
58

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Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Modelling of Material Removal and Product Quality

the energy content of a single spark is given as

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Analytical Results and Formulae:

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Fig 3.1 P-Diagram for STATIC Problems

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Fig.3.2 P-Diagram for DYNAMIC problems

8-Steps in Taguchi Methodology

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Identify the main function, side effects, and failure mode

Identify the noise factors, testing conditions and quality characteristics

Identify the objective function to be optimized

Identify the control factors and their levels

Select the orthogonal array matrix experiment

Conduct the matrix experiment

Analyze the data; predict the optimum levels and performance

Perform the verification experiment and plan the future action

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Quality Engineering Principles

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Quality Loss Function & the Fraction Defective Fallacy

Reject Good Bad Good

Accept Good Good Good

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

Quality loss L(y) A

Fig. Quality loss as a step function and quadratic function

Department of Mechanical Engineering M.M.M. Engineering College Gorakhpur

Study of EDM and Optimization of its machining parameters

L()y Quality loss

m L=K(Y-m)^2 Fig. Quadratic Quality Loss

Study of EDM and Optimization of its machining parameters

L()y Quality loss

Fig. Quality loss function for Nominal the best type

Smaller the better type

Fig. Quality Loss for smaller the better type