MODELLING AND OPTIMIZATION OF WIRECUT

EDM PROCESS USING INCOLOY 800 BY GREY

RELATION ANALYSIS AND RESPONSE SURFACE
METHODOLOGY

A PROJECT REPORT
Submitted By
KARTHICK .S 513317114017
THIRUNAVUKKARASU .S 513317114046
VEERA .R 513317114047
MURASOLIMARAN .P 513317114701

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

UNIVERSITY COLLEGE OF ENGINEERING ARNI

(A Constituent College of Anna University, Chennai)

ANNA UNIVERSITY: CHENNAI-600 025

AUGUST 2021

i
 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “MODELLING AND OPTIMIZATION OF

WIRECUT EDM PROCESS USING INCOLOY 800 BY RESPONSE
SURFACE METHODOLOGY” is the bonafide work of “KARTHICK.S
(513317114017),THIRUNAVUKKARASU.S(513317114046),VEERA.R
(513317114047),MURASOLIMARAN.P (513317114701)” who carried out
the project work under my supervision.

SIGNATURE SIGNATURE

Dr. P. SaravanakumarM. Tech, Ph.D., Dr. K. Sivasakthivel M.E, MBA., Ph.D.,

HEAD OF THE DEPARTMENT SUPERVISOR
Mechanical Department Mechanical Department
University College of Engineering Arni University College of Engineering Arni
Arni 632326. Arni 632326.

Submitted for the practical examination held on …………………..

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGMENT

At the outset, we express our deep gratitude to the almighty lord

forBestowing his grace and blessings upon to complete the project.

We express our thanks to Dr.R.ARULARASAN.,M.Tech.,Ph.DOur

beloved Dean who has given an opportunity to carry out the project work and
completing the same.

We honestly thank Dr. P. SARAVANAKUMAR., M.Tech., Ph.D.,Head

of the Department, Mechanical Engineering for his kind permission to carry out
this project work.

Our sincere thanks to our project guide

Dr.K.SIVASAKTHIVELM.E,M.B.A.,Ph.D.,Who helped us in all moments of
our project with his valuable suggestions and innovative ideas to complete our
project in successful way.

We would also like thank our project coordinator

Dr.A.MADHANAGOPAL.M.E.,Ph.D.,Asst.Professor,Mechanical Department
for his excellent guidance, support, wishes and blessings that
Inspired to the very height of sincerity leading us all the way to reach the goal.

We thank our beloved parents for providing a huge financial assistance

and support for completion of this project.

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 ABSTRACT

An attempt made to optimize the wire cut EDM of Incoloy 800 using

taguchi based grey relational analysis and response surface methodology. This

optimization method provides reliable, fast and efficient that can provide a

suitable solution to many problems faced by manufacturing industries today.

Incoloy metal of future, selected as project work piece material in the

experiment carried as per the design of experiments approach to minimize cost,

time, maximize productivity and quality.

Significant parameters such as pulse on time, pulse off time, wire feed rate,

servo voltage and Response variables tool wear, material removal rate and kerf

considered for the project work.

Experiments were conducted using Lꝯ orthogonal array. The degree of effect in

each process parameter on the individual response variables analysed from the

experimental results obtained using weighted grey relational grade. The

influence of each process parameter is carried out using analysis of variance. In

addition to RSM method is used for modelling and effect of process parameter

on output variables.

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 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT IV
LIST OF TABLE VIII
LIST OF FIGURES IX
LIST OF SYMBOLS AND ABBREVATIONS X

1. INTRODUCTION 11
1.1 WIRECUT EDM PROCESS 12
1.2 EQUIPMENT 12
1.3 POSITIONING SYSTEM 12
1.4 WIRE DRIVING SYSTEM 13
1.5 POWER SUPPLY 14
1.6 DIELECTRIC SYSTEM 15
1.7 PROCESS PARAMETERS 16
1.8 PROCESS CAPABILITIES 16
1.9 APPLICATIONS 17
1.10 WEDM AND ITS IMPORTANCE 19
1.11 WIRECUT EDM PROCESS 20
1.12 ADVANTAGES 21
1.13 DISADVANTAGES 21
1.14 SCOPE OF RESEARCH 22

2. LITERATURE REVIEW
2.1 REVIEW OF LITERATURE 23

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3. RESEARCH METHODOLOGY
3.1 CHARACTERISTICS 33
3.2 PHYSICAL PROPERTIES 33
3.3 CHEMICAL PROPERTIES 33
3.4 APPLICATIONS OF INCOLOY 34
3.5 SELECTION OF MATERIAL 36
3.6 SELECTION OF PARAMETERS 36
3.7 INPUT VARIABLES 38
3.8 RESPONSE VARIABLES 39
3.9 DESIGN OF EXPERIMENT 40

4. OPTIMIZATION OF TAGUCHI BASED

GREY RELATION ANALYSIS AND RSM
4.1 INTRODUCTION 42
4.2 GREY RELATION ANALYSIS 43
4.3 METHODOLOGY 46
4.4 PRINCIPAL COMPONENT ANALYSIS 47
4.5 CONFIRMATION EXPERIMENT 47
4.6 SUMMARY 48

5. EXPERIMENTAL PROCDURE,RESULT AND

DATA ANALYSIS
5.1 EXPERIMENTAL PROCEDURE 49
5.2 BASED ON TAGUCHI METHOD 50
5.3 MACHINING N WEDM 50
5.4 CALCULATION 51
5.5 RESULT AND DATA ANALYSIS 59
5.6 METHOD 61

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6. CONCLUSION 74

REFERENCE 75

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 LIST OF TABLES

3.1 SPECIFICATION OF WEDM 35

3.2 CHEMICAL COMPOSITION 36

3.3 PHYSICAL AND MECHANICAL PROPERTIES 36

3.4 SELECTION OF PARAMETERS 37

3.5 ORTHOGONAL ARRAY 41

5.1 EXPERIMENTAL DESIGN 50

5.2 EXPERIMENTAL RESULT 54

5.3 DATA FOR 9 COMPARABILITY SEQUENCES 56

5.4 CALCULATED GREY RELATIONAL

COEFFICIENT 58

5.5 WEIGHTED GREY RELATIONAL GRADE

AND ITS ORDER 58

5.6 RESPONSE TABLE FOR GREY RELATIONAL

GRADE

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 LIST OF FIGURES

FIGURE NO. FIGURE PAGENO.

1.1 WEDM 19

1.2 Schematic diagram of WEDM 20

3.1 Incoloy800 33

3.2 Selection of Material 35

5.1 Before machining 52

5.2 After machining 52

5.3 Surface plot of C6 vs C12,C10 63

5.4 Surface plot of C6 vs C13,C10 63

5.5 Surface plot of C6 vs C12,C13 64

5.6 Surface plot of C6 vs C10,C13 64

5.7 Contour plot of C6 vs C12,C10 65

5.8 Contour plot of C6 vs C13,C10 65

5.9 Contour plot of C6 vs C12,C13 66

5.10 Contour plot of C6 vs C10,C13 66

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LIST OF SYMBOLS AND ABBREVATION

b - kerf
dw - wire diameter
s - gap between tool and workpiece
vf - wire feed
h - height
MRR - material removal rate
Nij - normalization matrix
d - diameter
cm - centimeter
kg - kilogram
AC - alternating current
Hr - hour
CNC - computer numerically controlled
MHZ - megahertz

10
 CHAPTER 1

INTRODUCTION

Electrical discharge wire cutting (EDWC),more commonly known as

wire - EDM is a spark erosion process used to produce complex two and three -
dimensional shapes through electrically conductive work pieces .Wire -EDM a
relative newcomer to manufacturing was first used on a limited basis beginning
in 1968. By 1975 its popularity was rapidly increasing because the process and
its capabilities were becoming better understood by industry. By 1982 it was
estimated that over 1500 wire- EDM machines were in use in the United States
alone .Wire-EDM differs from conventional EDM in that a thin 0.05-0.30mm in
diameter wire performs as the electrode .The wire unwinds from a spool feeds
through the work pieces and is taken Figure wire-EDM,CNC machining with a
wire electrode (courtesy McWilliams machinery sales , Bridgeport machines
division of Textron, Farmington Hills, Mich.) up on a second spool.Wire cut
EDM equipmentis run by computer numerically controlled(CNC)
instruments,which can control the wire on a three dimensional axis to provide
greater flexibility.Simple cuts are done by varying the x-y coordinates of the
cutter with more complex cuts achieved by adding axes of motion to wire
guides.Both four and five axis wire EDM machines and service are available.
Whereas conventional EDM cannot always produce tight corners or very
intricate patterns.Manufracturer continue to produce thinner wire to allow for
smaller kerfs and even finer precision. It is important to remember that the wire
in the process is constantly moving,and not to be reused.As a result ,the
copper,brass,or other metallic wire can be miles long ,adding cost to the process.

11
1.1. WIRECUT EDM PROCESS

A DC power supply delivers high- frequency pulses of electricity to the

wire and the work pieces. The gap between the wire and work pieces is flooded
with deionized water which acts as the dielectric. Unlike conventional EDM the
work pieces in wire-EDM is almost never submerged in dielectric fluid. Instead
a localized stream is used .Material is eroded ahead of the traveling wire by
spark discharge which are identical with those in conventional EDM. Either the
work piece or the wire can be moved to cause the wire to cut similarly to a band
saw. There is no mechanical contact between the wire and the work piece in
wire-EDM .The wire work piece gap usually ranges from 0.025 to 0.05 mm and
is constantly maintained by a computer controlled positioning system.

1.2 EQUIMENT

With wire-EDM technology complicated cut outs can be made through difficult
to machine metals without the need to use either high cost grinding or expensive
formed EDM electrodes. The high degree of accuracy obtainable and the fine
surface finishes make wire- EDM particularly valuable for applications
involving the manufacture of press stamping dies, extrusion dies, prototype
parts, and even for the fabrication of conventional EDM electrodes. Further
because the operation is computer controlled and involves relatively long cycles
it is possible for one operator to tend several machines.

A wire-EDM machines consists of four subsystems the positioning system, the

wire drive system the power supply and the dielectric system. All four of these
subsystems have distinct differences from conventional EDM.

1.3 POSITIONING SYSTEM

Wire EDM positioning systems usually consist of a CNC two axis table and in
some cases an additional multi axis wire positioning system .The most unique

12
feature of the CNC system is that it must operate in an adaptive control mode to
always insure the consistency of the gap between the work piece If the wire
should come in contact with the work piece or if a small piece of material
bridges the gap and causes a short circuit the positioning system must sense this
conditional and backup along the programmed path to the proper cutting gap
conditions.

Linear cutting rates with wire EDM are slow typically less than 100 mm/hr in
25 mm thick steel .Therefore the block processing time (processing speed) of
the CNC system is not as important as it is with other high speed processes.

Because of the slow speed of the process it is not usual for job to be run
continuously for 10 or 20h r unattended. To facilitate unattended operation wire
EDM CNC systems are usually provided with a battery powered backup system
in case of power failure should occur the system will automatically restart itself
at the proper location so that work can resume without human intervention.

1.4 WIRE DRIVING SYSTEM

The function of the wire drive is to continuously deliver fresh wire under
constant tension to the work area .The need for constant wire tension is
important to avoid problems as taper, machining streaks, wire breaks, and
vibration marks. Several stages of preparation are incorporated into wire
delivery systems to ensures wire straightness. After wire leaves the supply
spool, it passes through the several wire feed and wire removal capstan rollers
these act to buffer the eroding zone from any disturbing influences created by
the wire supply.

As the wire passes through the work piece, it is guided by set of sapphire or
diamond wire guides. Before being collected by take up spool, it passes through
a series of tensioning rollers. Many wire EDM systems are using massive

13
granite slab as the machine base to further wire guarantee wire accuracy and
stability.

Automatic wire threading is a recently introduced feature that boosts

productivity. It automatically re threads the wire after breakage and enable a
wire EDM machine to run unattended. In addition, this feature is beneficial for
making progressive dies because it permits continual EDM machining of the
respective cavities without the need for human intervention (production,
1981).The most popular wire materials are chosen partly by the diameter of the
wire being used .When wire diameters are relatively large, i.e., 0.15-0.30 mm ,
copper or brass is used. However when very fine wire, approximately 0.03-0.15
mm in diameter required, the additional strength derived from molybdenum
steel wire is necessary.

As the wire passes through the work piece, the major portion of the spark
discharges occur at the leading surface of the wire. As a result, the wire is no
longer round after one pass through the work piece and it is discarded.
Fortunately, wire costs are low. Current prices for common wire types equate to
a maximum cost of less than74.01 rupees / hr, a cost that varies with different
unreeling rates. Faster rates are used when cutting thicker materials. Wire is
readily available in spools of approximately 3.63 kg and, on the average, is
consumed at the rate of 28.3gr/hr.

1.5 POWER SUPPLY

The most pronounced differences between the power supplies used for wire-
EDM and conventional EDM are the frequency of the pulses used and the
current. To produce the smoothest surface finished possible, pulse frequency as
high as 1 MHZ may be used with wire EDM. Such as high frequency ensure
that each spark removes as little material as possible, thus reducing the size of
the EDM “craters”.Because the diameter of the wire used is small, its current

14
carrying capability is limited .Because of this limitation, wire EDM power
supplies are rarely built deliver more than 20 amp of current.

1.6 DIELECTRIC SYSTEM

Deionized water is the dielectric used for the wire EDM process. Deionized
water is used for four reasons,

 Low viscosity
 High cooling rate
 High MRR
 No fire hazard

The small cutting gap used with wire EDM mandates that a low viscosity
dielectric be used to ensure adequate flushing. Water meets this criterion. Water
can also remove heat from the cutting area much more efficiently than
conventional dielectric oils more efficient cooling results in extremely thin
recast layers.Very high specific material removal rates can be achieved when
using water as the dielectric, however the wear rate on the tool (wire) is also
high. Because the wire is not reused, the high tool wear rate is of no
consequence. This explains why water is not commonly used with conventional
EDM.

Finally, because of the slow processing speeds of wire EDM, many users run
their most time consuming jobs over night or over the weekend unattended.
With conventional EDM the use of flammable dielectric oils present a fire
hazard, cancelling this option. When using water for the dielectric, the fire
hazard problem is eliminated .Rather than submerge the entire part into
deionized water, local delivery is most often used. Some systems deliver the
dielectric fluid via a hose directed at the cut interface. The most efficient
method of dielectric delivery (with respect to flushing) is to provide a stream of
deionized water coaxial with the wire .Deionized water dielectric systems reuse
15
the water to minimize operating costs. Often, this is accomplished by first
filtering the collected water with 5 microns this possible paper filters. After
filtration the water resistivity is corrected by passage through a mixed bed
deionized cartridge. If a steel part is to be processed for an extended period,
special additives can be mixed with the water to avoid rust formation on the part
surfaces, for if rust forms, an extra polishing operation is generally required to
remove the oxides.

Currently, many companies throughout the world manufacture wire EDM

machines with part capacities of up to 300 cm² and weights of up to 1360 kg .In
addition to the machine, most wire EDM users also purchase CAD tape
preparation units which drastically reduce time required to prepare complex
program paths and help to facilitate such program edits as wire offset and part
scaling.

1.7 PROCESS PARAMETER

The linear cutting rate for wire EDM is approximately 38-115 mm/hr in 25 mm
thick steel or approximately 20 mm/hr in 76 mm steel the linear speed is
dependent upon the thickness of the material not upon the shape of the cut. The
linear cutting rate is the same whether a straight cut or complex curves are being
generated .The speed of the wire passing through the work piece can vary from
8-42 mm/sec depending upon cutting conditions.

Special precautions must be taken when cutting sintered carbides and various
cutting tool insert materials. These materials must be machined with as little
voltage as possible to avoid electrolysis from selectively removing the cobalt
binder at the cut edge.

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1.8 PROCESS CAPABILITIES

Wire EDM is a specialized process that is capable of machining electrically

conductive work pieces to produce fine finishes, extremely high accuracies and
cut edges that have a smooth, matte finish .The matte finish is a result of the
thousands of microscopic pits remaining from the spark erosion. When applied
to punch and die applications, the oil retaining quality of these micro pits has
been known to increase die life .Surface finishes ranging from 0.12 to 0.25 µ (5
to 10 µ) are routinely obtained and by utilizing a second “Finish passes” can be
achieved at linear traverse rates as fast as 380 mm/hr .Many wire EDM
machines are available with a positioning resolution of 0.001 and can routinely
obtain accuracies of ± 0.007 mm with special care , accuracies of ± 0.0025 mm
over 152 mmare possible.

However to achieve such results, care must be taken to ensure the uniformity of
the wire diameter, and the temperature and resistivity of the dielectric must be
closely controlled.

The minimum internal corner radius wire EDM is able to produce is limited
only by the diameter of the wire being used. External corners can be produced
with a radius as small as 0.038 mm .The extreme accuracies that can be obtained
with wire EDM systems make possible the creation of punches and dies with
true line to line zero clearance fit.

1.9 APPLICATIONS

Although wire EDM is a relatively slow cutting process, it has the ability to do
jobs that are traditionally performed by an increasingly smaller number of
highly skilled die makers and without the associated high labour costs. The
machines ability to operate unattended for hours or even days further increases
the attractiveness of the process. Machining thick sections of material, as thick
as 200 mm, in addition to using the computer to accurately scale the size of the
17
part, make this process especially valuable for the fabrication of dies of various
types .The machining of press stamping dies is simplified because the punch,
die, punch plate, and stripper all can be machined from a common CNC
program. Clearances are provided by modifying the basic program with an
automatic scaling routine. Because clearances can be controlled so accurately, it
is possible to increase die life by as much as seven to ten times .An example of
the savings possible with wire EDM when applied to the fabrication of a 25 mm
thick stamping die In this example, the stator core stamping die is machined by
wire EDM after preliminary conventional machining and heat treatment
.Another popular application for wire EDM is the machining of extrusion dies
and dies for powder metal (PM) compaction. The PM dies, which are typically
two to four times thicker than normal dies, requires the machining of details
with high aspect ratios. With wire EDM, this is easily achieved without taper
and without long manual machining times.

The present application of WEDM process includes automotive, aerospace, tool

and die making industries. WEDM applications can also be found in the
medical, optical, dental, jewellery industries, and in the automotive and
aerospace R & D areas. The machines ability to operate unattended for hours or
even days further increases the attractiveness of the process.

1.10 WEDM AND ITS IMPORTANCE

WEDM is considered as a unique adoption of the conventional EDM process,

which uses an electrode to initialize the sparking process. WEDM process with
a thin wire as an electrode transforms electrical energy to thermal energy for
cutting materials. WEDM is one of the non-traditional machining method, such
materials are difficult to machine by traditional machining methods. Hence they
are used non-traditional method .Wire electrical discharge machining (WEDM)
technology has grown tremendously since it was first applied more than 30
years ago. In 1974 the optical- line follower system to automatically control the
18
shape of the components to be machined by the WEDM process. By 1975, its
popularity rapidly increased, as the process and its capabilities were better
understood by the industry. It was only towards the end of the 1970s, when
computer numerical control (CNC) system was initiated into WEDM, which
brought about a major evolution of the machining process.

Its broad capabilities have allowed it to encompass the production, aerospace

and automotive industries and virtually all areas of conductive material
machining. This is because WEDM provides the best alternative or sometimes
the only alternative for machining conductive, exotic, high strength and
temperature resistive materials, conductive engineering ceramics with the scope
of generating intricate shapes and profiles. WEDM has tremendous potential in
its applicability in the present day metal cutting industry for achieving a
considerable dimensional accuracy, surface finish and contour generation
features of products or parts. Moreover, the cost of wire contributes only 10% of
operating cost of WEDM process.The difficulties encountered in the die sinking
EDM are avoided by WEDM, because complex design tool is replaced by
moving conductive wire and relative movement of wire guides.

Fig.no. 1.1 WEDM

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1.11 WIRE CUT EDM PROCESS

Work piece to be machined is mounted on the table by the application of control

unit. A very small hole is predrilled in the work piece, through which a thin wire
is made of brass or molybdenum is passed and this wire is operated by wire feed
mechanism. Dielectric fluid is passed over the work piece and tool by using
pump. When D.C supply is applied to the circuit a spark produced across the
gap between work piece and tool. The voltage across the gap is sufficiently
large, a high power spark is produced. This spark produced in an interval of 10 -
30 microseconds and the current density in the range of 15- 500 A/mm2 , so
thousands of spark produced across the small gap, which results in the
temperature of 100000 c.At this high temperature and pressure the material is
eroded and melted and some of its vaporized. The metal is removed in this way
of from the work piece..A wire EDM machine consists of four subsystems: The
positioning system, the wire drive system, the power supply and the dielectric
system. All four of these subsystems have distinct differences from
conventional EDM.

Fig.no.1.2 Schematic diagram of WEDM

20
Linear cutting rates with wire EDM are slow, typically less than 100mm per
hour in 25mm thick steel. Therefore the block – processing time of the CNC
system is not as important as it is with other high speed processes. Because of
the slow speed of the process, it is not unusual for jobs to be run continuously
for 10 or 20 hr unattended. To facilitate unattended operation, wire –EDM CNC
systems are usually provided with a battery powered backup systems in case a
power failure occurs during a run. If a power failure should occur, the system
will automatically restart itself at the proper location so that work can resume
without human intervention. Automatic wire threading is a recently introduced
feature that boost productivity. It automatically re-threads the wire after
breakage and enables a wire EDM machine to run unattended.In addition this
feature is beneficial for making progressive dies because it permits continual
EDM machining of the respective cavities without the need for human
interventions.

1.12 ADVANTAGES

1.12.1 Manufacturing of electrode

In this process very thin wire made of brass and molybdenum is used as a
electrode to machine the work piece material. This feature creates no need of
manufacturing electrode in traditional methods and reduced man – hour relation
and greater economy.

1.12.2 Electrode wear

During the process wire electrode is constantly fed into the work piece, so the
wear rate is practically ignored.

21
1.12.3 Surface finishing

This process wire is passed at speed about 10-30 mm/s by wire feed mechanism.
So machining is continued without any accumulation of chips and gases. It
gives high surface finish and reduce manual finishing time.

1.12.4 Complicated shapes

By using program, complicated shapes and very minute shapes are produced
there is no need of skilled labors.

1.12.5 Time utilization

Since all machine motion of wire cut EDM is controlled by NC type, it can be
operated throughout the day without any fire hazardous.

1.12.6 Straight holes

The electrode wire is maintained at optimum tension level by a unique wire-

tension control mechanism. So, it prevents taper hole, barrel shaped holes, wire
breakage and wire vibration.

1.13 DISADVANTAGES

 Capital cost is high

 Cutting rate is low
 It is not suitable for large work piece

1.14 SCOPE OF RESEARCH

To determine optimum machining parameter leading to minimum kerf,

minimum tool wear rate, maximum material removal rate, increase quality of
the product and reduced the production cost by using the optimization technique
of Response surface method.

22
 CHAPTER 2

LITERATURE SURVEY

INTRODUCTION
This section describes the milestones attained in specific research work,
previously conducted and concluded experimentally with a similar result which
shows the difficulties and challenges to over-come at this particular area of
research. Additionally, it provides the standard regulation need to considered
and formulation of various correlations analytically. Also it gives a clear view
of machinability studies carried out on metal matrix composites using different
optimization and condition monitoring. The review primarily focus on the
machinability of various materials, the effect of machining process parameter on
response parameter like tool wear, material removal rate and kerf. It also
discusses the outcomes of single and multi-response optimization techniques for
the optimization of machining parameters. The following are major research
articles refered.

2.1 REVIEW OF LITERATURE

1. Arun Kumar Srirangan, SathiyaPaulrajdiscussed that,Incoloy 800HT

which was selected as one of the prominent material for fourth generation
power plant can exhibit appreciable strength, good resistance to corrosion
and oxidation in high temperature environment. This study focuses on the
multi-objective optimization using grey relational analysis for
Incoloy800HT welded with tungsten inert arc welding process with N82
filler wire of diameter 1.2 mm. The welding input parameters play a vital
role in determining desired weld quality. The experiments were
conducted according to L9 orthogonal array. The input parameter chosen
were the welding current, Voltage and welding speed. The output

23
 response for quality targets chosen were the ultimate tensile strength and
yield strength (at room temperature, 750 °C) and impact toughness. Grey
relational analysis was applied to optimize the input parameters
simultaneously considering multiple output variables. The optimal
parameters combination was determined as A2B1C2 i.e. welding current
at 110 A, voltage at 10 V and welding speed at 1.5 mm/s. ANOVA
method was used to assess the significance of factors on the overall
quality of the weldment. The output of the mechanical properties for best
and least grey relational grade was validated by the metallurgical
characteristics.

2. El-Taweel.T.A, Hewidy.M.S, El-Safty.M.F, 2005.discussed that,Wire

electrical discharge machining (WEDM) allowed success in the
production of newer materials, especially for the aerospace and medical
industries. Using WEDM technology, complicated cuts can be made
through difficult-to-machine electrically conductive components. The
high degree of the obtainable accuracy and the fine surface quality make
WEDM valuable. The right selection of the machining conditions is the
most important aspect to take into consideration in processes related to
the WEDM of Inconel 601 material. Inconel is one of the recent materials
that are developed to be hard, strong and temperature resistant. The
present work highlights the development of mathematical models for
correlating the inter-relationships of various WEDM machining
parameters of Inconel 601 material such as: peak current, duty factor,
wire tension and water pressure on the metal removal rate, wear ratio and
surface roughness. This work has been established based on the response
surface methodology (RSM).

3. Harman preet, Harvinder Lal, Gaurav Dhuria. They

researchedthat,The experimentation has been performed on EDM for the

24
 modelling and optimization of the process parameters. In this
workmodelling of the processes are done by artificial neural networking
and optimization by genetic algorithm. For fitness function regression
analysis has been performed. Design of experiment with mixed level L18
orthogonal array has been considered. All experiments were performed on
INCOLOY-800. Copper as an electrode considered. In this work TWR
considered as the response variable. Dielectric fluid with two level; where
current, pulse on time and gap voltage considered with three levels as the
process parameters. 4-17-1-1 network considered in ANN by feed
forward back propagation for process modelling. Two types of dielectric
fluid considered as kerosene and EDM oil. For multi objective-
optimization Genetic Algorithm used (GA)

4. J.M.Pujara, K.D.Kothari. andA.V.Gohil. (2018),They discussedElectro

chemical discharge hybrid machining process involves in micro-
machining to cut micro-channel, micro-profile as well as micro-slot, blind
hole on hard materials like ceramic, quartz and glass. Experimentation
has been performed using an indigenously developed micro-ECDM set up
in which pressurized automated spring feeding mechanism and cam
follower system is used to control the working gap. This paper emphasis
to the influences of different process parameters like applied voltage (V),
electrolyte concentrations (wt%), pulse frequency (Hz) and duty ratio (%)
on different machining performance characteristics such as Material
Removal Rate (MRR), Overcut (OC),Surface Roughness (Ra) and Heat
Affected Zone (HAZ) during micro-channel cutting on glass. The
empirical mathematical model has been validated by the analysis of
variances. This research paper rendered the suitable optimal parametric
condition during single as well as multi objective optimization using
genetic algorithm (GA). Applied voltage and duty ratio has dominating

25
 role to increase MRR, OC, HAZ and surface roughness. Machining Depth
increased using automated spring feeding with Cam-follower mechanism
and achieved machining depth of 1.35mm. This research paper also
presented the SEM analysis of micro-channel to find out the debris and
other particles.

5. Juhr.H, Schulze.H.P, Wollenburg.G, Kunanz.K, 2004. They

researched many applications the wire-EDM of cemented carbides
(WEDM) (WC-(TiC)-Co) is restricted by the basic properties of this
family of materials. Therefore, this research was aimed at developing an
optimal process energy source that produces improved material properties
after WEDM.The studies showed that it is important to use the correct
parameter selection for main-cut and post-cut. Deterioration in the
material properties by processing with high pulse energies can be
corrected only by a limited extent in the post-cut. The primary actuating
variable of pulse is the pulse duration, i.e. with pulse duration <500ns
higher current magnitudes can also be used without problems. Through
the use of a new process energy source increase of bending strength of
average 30% could be achieved.Simulation of the pulse waveforms and
how the thermal load of the cut surface can be reduced and the technical
conditions can be adapted to a particular application are shown in this
paper.

6. Kanlayasiri.S, Boonmung.S, 2007. They discussed anDC53 is a newly

developed cold die steel from Daido Steel, Japan. It is an improvement
over the familiar cold die steel SKD11. Because DC53 is a new die steel,
only little information is available in literature for its machining
characteristics. This paper investigated the effects of machining
parameters on surface roughness of wire EDMed DC53 die steel. The
investigated machining parameters were pulse-on time, pulse-off time,

26
 pulse-peak current, and wire tension. Analysis of variance (ANOVA)
technique was used to find out the parameters affecting the surface
roughness. Assumptions of ANOVA were discussed and then examined
through residual analysis. Quantitative testing methods on residual
analysis were employed in place of the typical qualitative testing
techniques. Results from ANOVA show that pulse-on time and pulse-
peak current are significant variables to surface roughness of wire-
EDMed DC53 die steel. The surface roughness of test specimen increased
as these two variables increased.

7. Kiran A Patela, Pragnesh K Brahmbhattba, They Researchedin this

paper the comparison of the surface roughness prediction models based
on response surface methodology (RSM) and artificial neural networks
(ANN) is described. The models were developed based on five-level
design of experiments conducted on Aluminum alloy 6061 work material
with spindle speed, interference, feed, and number of tool pass as the
roller burnishing process parameters. The ANN predictive models of
surface roughness was developed using a multilayer feed forward neural
network and trained with the help of an error back propagation learning
algorithm based on the generalized delta rule. Mathematical models of
second order RSM and developed ANN models were compared for
surface roughness. The comparison evidently indicates that the prediction
capabilities of ANN models are far better as compared to the RSM
models. The minutiaeof experimentation, development of model, testing,
and performance comparison are presented in the paper.

8. Ko-Ta Chiang, Fu-Ping Chang, De-Chang Tsai, 2006. They discussed

rapidly resolidified layer is formed by the re-solidification of residual
molten material on the machined surface during the electric discharge
machining (EDM) process. This paper presents a systematic methodology

27
 for modeling and analysis of the rapidly resolidified layer of spheroidal
graphite (SG) cast iron in the EDM process using the response surface
methodology (RSM). The factors of second phase considered are the
quantity, diameter, and area fraction of spheroidal graphite particle. The
performance of rapidly resolidified layer in terms of the layer thickness
and ridge density are response variables investigated. Experimental plan
is performed by a standard RSM design called a central composite design
(CCD). The results of analysis of variance (ANOVA) indicate that the
proposed mathematical model obtained can adequately describes the
performance within the limits of the factors being studied. The
conclusions reveal that the quantity and area fraction of graphite particle
are the most influential factors on the layer thickness and ridge density.
The formation of ridge is chiefly related to the quantity and area fraction
of graphite particle. In addition, the layer thickness reduces as the
diameter of graphite particle increases.

9. Liao.Y.S, Huang.J.T, Chen.Y.H.A, 2003. The objective of this project

is to study the effect of machining parameters of wire electrical discharge
machining (WEDM) on TITANIUM, which are now widely used in many
medical, aerospace applications due to their high technical benefits.
Conventional method of machining the material will damages the work
piece due to chipping, presence of burrs and cracking. Wire cut Electrical
discharge machining (WEDM) techniques have been already tried with
other materials, which is difficult to cut to prove the feasibility of
machining the titanium. Hence as steps a head wire electrical discharge
machining process is to be used to machine the material (titanium) and
the effect of various control parameters on the response parameters were
studied. As a part of the project, titanium is machined in wire cut EDM

28
 machine and the optimal combination of control parameters were found to
get higher metal removal rate and surface finish using Taguchi method

10. Mandeepkumar and Hari singh. (2016),The effective optimization of

machining process parameters affects dramatically the cost and
production time of machined components as well as the quality of the
final products. This paper presents the optimization aspects of a Wire
Electrical Discharge Machining operation using Inconel X-750 as work
material. The objective considered in this study is minimization of the
dimensional deviation. Six input process parameters of WEDM namely
spark gap voltage, pulse-on time, pulse-off time, wire feed rate, peak
current and wire tension, were chosen as variables to study the process
performance. Taguchi's design of experiments methodology has been
used for planning and designing the experiments. The analysis of variance
was carried out for raw data as well as for signal to noise ratio. Four input
parameters and one two-factor interaction have been found to be
statistically significant for their effects on the response of interest. The
confirmation experiments were also performed for validating the
predicted results.

11. Muthu Kumar V, Suresh Babu A, Venkatasamy R and Raajenthiren

M,2010. The present work demonstrates optimization of Wire Electrical
Discharge Machining process parameters of Incoloy800 super alloy with
multiple performance characteristics such as Material Removal Rate
(MRR), surface roughness and Kerf based on the Grey–Taguchi Method.
The process parameters considered in this research work are Gap Voltage,
Pulse On-time, Pulse Off-time and Wire Feed. Taguchi’s L9 Orthogonal
Array was used to conduct experiments. Optimal levels of process
parameters were identified using Grey Relational Analysis and the
relatively significant parameters were determined by Analysis of

29
 Variance. The variation of output responses with process parameters were
mathematically modelled by using non-linear regression analysis method
and the models were checked for their adequacy. Result of confirmation
experiments shows that the established mathematical models can predict
the output responses with reasonable accuracy.

12. Pratik A. Patil, C.A. Waghmare(2014),Wire electrical discharge

machining has become an important non-traditional machining process,
as it provides an effective solution for producing components made of
difficult-to-machine materials like tungsten carbide, titanium, zirconium
etc., and intricate shapes, which are not possible by conventional
machining methods. This research paper deals with Response Surface
Methodology approach for maximizing the material removal rate in wire
electrical discharge machining. The investigated machining parameters
were wire tension, pulse on time and peak current. Machining was carried
on AISI D2 cold work steel, which is widely used in die and mold making
industries. The experiments were designed based on response surface
design method; in which central composite design method was applied
for fitting the second order model. After the experimentation, the effect of
the parameters on MRR was determined by analysis of variance
(ANOVA). Also the interaction of their parameters was considered for
their significance. Regression analysis was done and a second order
mathematical model was fitted for MRR considering the parameters and
their significant interactions. And at last optimization was carried using
desirability approach and confirmation experiments were performed.

13. Saurav Datta, SibaSankarMahapatra , In the present work, quadratic

mathematical models have been derived to represent the process behavior
of wire electrical discharge machining (WEDM) operation. Experiments
have been conducted with six process parameters: discharge current,

30
 pulse duration, pulse frequency, wire speed, wire tension and dielectric
flow rate; to be varied in three different levels. Data related to the process
responses viz. material removal rate (MRR), roughness value of the
worked surface (a measure of surface finish, SF) and kerf have been
measured for each of the experimental runs; which correspond to
randomly chosen different combinations of factor setting. These data have
been utilized to fit a quadratic mathematical model (Response Surface
Model) for each of the responses, which can be represented as a function
of the aforesaid six process parameters. Predicted data have been utilized
for identification of the parametric influence in the form of graphical
representation for showing influence of the parameters on selected
responses.

14. Vinit Raut, Mrs. Meeta Gandhi, MrNileshNagare, Mr.

AniketDeshmukh. (2016),In this report the effect of Process parameters
on material removal rate(MRR) and surface roughness of HCHCR-
D2(high carbon high chromium steel) die steel are investigated as MRR
and Surface roughness in W-EDM(wire electrical discharge machining)
are of crucial importance and Taguchi L9 orthogonal array and Grey
Relational Analysis techniques are used for optimization of parameters.
For experimentation Pulse on time (Ton), Pulse off time (Toff), Peak
current (Ip), and wire feed rate(Wf) are taken as input parameters while
MRR and Surface roughness are taken as output parameters. For each
experiment Surafce roughness is calculated by using Surface finish tester
and MRR is calculated by measuring the difference in weight of
workpiece before and after machining with time required for machining.

31
 CHAPTER 3

RESEARCH METHODOLOGY

INCOLOY 800

Incoloy 800 is the nickel-iron-chromium alloy which shows different

characteristics and shows its use in a vast number of applications. This alloy is
capable of maintaining the austenitic structure. This nickel steel alloy has a high
level of carbon in 800 H and there is also added 1.20 % aluminum as well as
titanium in this 800HT alloy. Incoloy 800 is the first alloy as it is slightly
modified in an Incoloy 800H. The modification was done to control the carbon
as well as the grain size in order to optimize stress rupture character. This nickel
alloy is a double certified and it combines the characteristics of both the forms
(800H/HT). Incoloy 800H/HT alloy is intended for the high temperature as well
as structural application. Nickel of this alloy makes it highly resistant to
chloride stress corrosion cracking as well as embrittlement from the
precipitation. In an annealed condition this alloy shows superior creep as well as
stress rupture properties. If we talk about the uses of the Incoloy 800 then it is
used in an application where there is temperature up to 1100°F. The chemical
balance enables the nickel steel alloy to show excellent resistance to the
oxidation, carburization as well as nitriding atmosphere. The Incoloy 800HT
Rod is not embrittled even after the large period of use in the 1200 to 1600° F
where various stainless steel becomes embrittle.

Types of Incoloy 800 bars:There are various forms in which the Incoloy 800
bars are offered some of which are the hex, round, rectangular, square, rolled
round bar.

32
 Fig.no 3.1 Incoloy 800

3.1 CHARACTERISTICS

 High creep rupture strength

 High-temperature strength
 Excellent corrosion resistance in the acidic environment
 Excellent resistance to sulfur-containing atmospheres
 Resistance to carburization as well as oxidation in the elevated
temperature environment

3.2 PHYSICAL PROPERTIES

Incoloy 800 alloy has good mechanical strength over a wide temperature range.
The equipment in which these are used is designed based on the tensile
properties. This alloy shows higher tensile strength at the room temperature.
Cold work substantially enhances the tensile properties of this alloy. This alloy
also shows high impact strength as well as remains hard at the cryogenic
temperatures. The compressive yield strength of this alloy is similar to tensile
yield strength.

33
3.3 CHEMICAL PROPERTIES

The carbon content present in Incoloy 800 alloy is proportional to creeping and
cracking properties of alloy such that more carbon content, more are the
creeping and cracking properties. Therefore carbon is added significantly in the
alloy on the base of special application requirements. Carbon is added by 0.05%
to 0.10% in the ASTM and ASME limits.

3.4 APPLICATIONS OF INCOLOY

 Ethylene furnace quench boiler

 Industrial furnaces
 Valves, fittings as well as in apparatus exposed to corrosive attack
 Heat treatment equipment
 Hydrocarbon cracking
 Pressure vessels
 A super heater as well as re heater in the power plants
 Petrochemical as well as chemical processing
 Heat exchangers

These alloys are widely used in an application which involves exposure to the
corrosive atmosphere as well as elevated temperatures like paper pulp industry
as well as nuclear power plants. Heat treatment equipment like trays, fixtures,
and baskets employ Incoloy 800H/HT. petrochemicals as well as chemical
processing industry uses this alloy for the piping system as well as heat
exchangers in nitric acid media mostly where resistance to chloride stress
corrosion is required. Power plant makes use of these alloys as a re-heater
tubing as well as super heater tubing.

34
Table 3.1 SPECIFICATION OF WEDM

Brand name Electronica

Model ULTRACUT-843
Max cut angle 15º
Accuracy of repeated positioning 0.001
Best surface roughness 0.001
Feeding speed 500
Machine weight 5 Ton
Max load of table 400*300*300
Max work piece weight 400*300*300
Positioning accuracy 0.001
Power capacity 240 volt
Precision 0.001
Table travel in mm 400*300
Wire feed rate 15m/min
Wire tension 500gms
Work table size 400*300

3.5 SELECTION OF MATERIAL

INCOLOY alloy 800 (UNS N08800/W. Nr. 1.4876) is a widely used

material for construction of equipment requiring corrosion resistance, heat
resistance, strength, and stability for service up to 1500°F (816°C).

Fig. no 3.2
35
Table 3.2 chemical composition

ELEMENT Wt%
Carbon 0.096
Chromium 20.096
Magnesium 0.501
Aluminium 0.302
Molybdenum 0.335
Nickel 34.991
Iron 42.821
Titanium 0.304
Tungsten 0.066
Vanadium 0.027
Cobalt 0.07

Table 3.3 Physical and Mechanical properties

Properties Unit Value

Density g/cm^3 7.94
Melting Range °C 1357-1385
Specific heat J/kg.k 460
Electrical Resistivity µΩ·m 989
Tensile strength Mpa 600
Yield strength Mpa 295
Elongation % 44
Hardness HB 138

36
3.6 SELECTION OF PARAMETERS AND LEVELS

The experimental setup is shown in the table. Based on the literature

review, the input parameters pulse on time, pulse off time, Wire feed and servo
voltage were varied to see their effect on the output variable.

Table 3.4 Input parameters and levels

INPUT LEVEL 1 LEVEL 2 LEVEL 3 UNIT

PARAMETER

Servo voltage 15 20 25 Volt

Pulse on time 108 112 114 µs
Pulse off time 60 58 56 µs
Wire feed 1 2 3 m/min

3.7 INPUT VARIABLES

3.7.1 Pulse on time

Pulse on time is the period for which the voltage is applied across the gap.
It is denoted by TON. Higher the TON setting larger is the pulse on period. The
single pulse discharge energy increases with increasing TON period, resulting in
higher cutting rate and poor surface finish.

3.7.2 Pulse off time

Pulse off time is the period for which voltage across the gap is absent. It
is denoted by TOFF. Higher the TOFF setting larger is the pulse off period. This
results in better surface finish.

37
3.7.3 Wire feed rate

Wire feed rate is the rate at which fresh wire is fed continuously for sparking.
Wire feed rate has great influence on MRR. With a wire feed rate of 8m/min,
brass wire spool of 5kg will last for about 24 hours.

3.7.4 Gap voltage

Gap voltage is the potential difference across the work piece and wire
electrode. It is read directly on the voltmeter. Gap voltage depends on the set
values of gap potentiometer and sensitivity potentiometer. Ranges between 40-
60V results in better MRR and fine finish. High gap voltage gives poor finish.

3.7.5 Peak Current

The peak current is represented by IP and it is the maximum value of the

current passing through the electrodes for the given pulse. The IP setting current
range available on the present WEDM machine is 10–230 ampere which is
applied in steps of 10 ampere. Increase in the IP value will increase the pulse
discharge energy which in turn can improve the cutting rate further. For higher
value of IP, gap conditions may become unstable with improper combination of
Ton, Toff, SV & SF settings. As and when the discharge conditions become
unstable one must reduce the IP value.

3.7.6 Wire tension

Wire Tension Wire tension determines how much the wire is to be

stretched between upper and lower wire guides. This is a gram-equivalent load
with which the continuously fed wire is kept under tension so that it remains
straight between the wire guides. More the thickness of job more is the tension
required. Improper setting of tension may result in the job inaccuracies as well
as wire breakage.

38
3.7.7 Flushing Pressure

Flushing Pressure is for selection of flushing input pressure of the dielectric.

The flushing pressure range on this machine is either 1 (High) or 0 (low). High
input pressure of water dielectric is necessary for cutting with higher values of
pulse power and also while cutting the work piece of more thickness. Low input
pressure is used for thin work piece and in trim cuts.

3.8 RESPONSE VARIABLES

3.8.1 Material Removal Rate

Maximum of MRR is an important indicator of the efficiency and cost

effectiveness of the WEDM process, however increasing MRR is not always
desirable for all applications since this may scarify the surface integrity of the
work piece. A rough surface finish is the outcome of fast removal rates.

MRR =Vf x h x b

Where,

vf = feed rate of wire into the work piece in mm/min,

h = work piece thickness or height in mm,

b = Kerf given by: b = dw + 2s

Where,

S = gap between work piece & tool in mm.

dw = wire diameter in mm.

3.8.2 Kerf

Kerf width is mainly depends on parameters pulse on time, pulse off time,
servo voltage and wire feed. Kerf width is the measure of the amount of
material that is wasted during machining. It determines the dimensional
39
accuracy of the finishing part. The internal corner radius to be produced in
WEDM operations are also limited by the kerf width.

3.8.3 Tool wear

Tool wear describes the gradual failure of cutting tools due to regular
operation. Tool wear is affected by the precipitation of carbon from the
hydrocarbon dielectric on the electrode surface during sparking.Tool wear rate
is expressed as the ratio of difference of the diameter of the tool before and after
machining.

3.9 DESIGN OF EXPERIMENTS

Design of Experiments (DOE) techniques enables designers to determine

simultaneously the individual and interactive effects of many factors that could
affect the output results in any design. DOE also provides a full insight of
interaction between design elements; therefore, it helps turn any standard design
into a robust one. Simply put, DOE helps to pin point the sensitive parts and
sensitise areas in designs that cause problems in Yield. Designers are then able
to fix these problems and produce robust and higher yield designs prior going
into production.

The design based upon the Taguchi L9 orthogonal array. Dr. Genich Taguchi, a
Japanese scientist contributed significantly to the field of quality engineering.
His quality philosophy is that quality should be designed into the product and
not inspected it.

40
Table 3.5 Standard Lꝯ orthogonal array

Trail no Parameters and levels

I II III IV
1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 2 1 2 3
5 2 2 3 1
6 2 3 1 2
7 3 1 3 2
8 3 2 1 3
9 3 3 2 1

41
 CHAPTER 4

OPIMIZAION OF TAGUCHI BASED GREY

RELATION ANALYSIS AND RSM

4.1 INTRODUCTION

Taguchi method is the accepted method of Design of an experiment

which has proven to produce high-quality products at subsequently low cost. Dr.
Genichi Taguchi developed a method known as orthogonal array design, which
adds a new dimension to the conventional experimental design. Taguchi
proposed a three-step approach named system, parameter, and tolerance design.
In system design, scientific and engineering knowledge used to produce a basic
functional prototype design. The objective of the parameter design is to identify
the product parameter values under the optimal process parameter. Tolerance
design deals problem of how, and when, to specify tightened tolerances for a
product or a process so that quality and performance/productivity are enhanced.

The following are steps in the Taguchi design

 Selecting the proper Orthogonal Array (OA) based on the number of

controllable factors (parameters)
 Running experiments based on the OA
 Analyzing data
 Identifying the optimum condition
 Conducting confirmation runs to check the method. The confirmation test is
conducted to verify the results and to predict the optimum condition at the
selected levels of significant parameters

42
4.2 GREY RELATIONAL ANALYSIS

Taguchi method is only suitable for optimization of the parameter for

a single response.It solved by the GREY system introduced by Deng. GRA was
proposed by Deng to solve multiple characteristics (Deng 1989). This method
alters multiple quality characteristics into single GREY relational grades. By
comparing the computed GREY relational grades, the arrays of respective
quality characteristics are obtained to select an optimal set of process
parameters by response grades

In GRA, data pre-processing required since the range and unit in one
data sequence may differ from the others. Data pre-processing is necessary
when sequence scatter range is too broad or when the directions of the target in
the sequence are different. Data pre-processing is a process of shifting the
original to a comparable sequence. For this purpose, the experimental results
normalized in the range between zero and one.

Depending on the characteristics of the data sequence, there are

various methodologies of data pre-processing available for the GRA. The
procedure discussed below.

 Identify the response variable and process parameters to evaluate.

 Check out the number of levels for the process parameters.
 Select the appropriate OA and assign the process parameters to the OA.
 Conduct the experiments as per the OA.
 Normalize the experimental results of MRR, TWR, temperature, power
consumption, surface roughness, and roundness.
 Get the GREY relational generating and calculate the GREY relational
coefficient.
 Calculate the GREY relational grade by averaging the GREY relational
coefficients.
43
 Analyze the experimental results by the GREY relational grade and
ANOVA.
 Select the optimal levels of process parameters.
 Confirm the optimal process parameters through the confirmation test

In the GREY relational analysis, experimental results regularized, and

then the GREY relational coefficient was calculated from the normalized
experimental data to express the relationship between the desired and actual
experimental data. Then, the GREY relational grade computed by averaging the
GREY relational coefficient corresponding to each process response
(6 responses). Overall evaluation of the multiple process responses based on the
GREY relational grade. Optimization of the complicated multiple process
responses transformed into the optimization of a single GREY relational grade.
In other words, the GREY relational grade treated as the overall evaluation of
experimental data for the multi-response process. Optimization is the level with
the highest GREY relational grade.

4.3 GREY RELATIONAL ANALYSIS METHODOLOGY

Step 1: Normalization of S/N ratio

Signal to noise ratio helps to determine the robustness of the

experiment. Normalization of the S/N ratio means to prepare raw data where the
original sequence transferred to a comparable sequence.Calculation of the
Signal to Noise (S/N) ratio for surface roughness, tool wear, roundness, power
consumption, and temperature calculated by Equation (4.1) by the lower, the
better concept.

(4.1)
44
 For material removal rate Signal to Noise (S/N) ratio is calculated by
Equation (4.2) by the Larger, the better concept.

(4.2)

where η represents the measure of quality characteristics, i.e., signal to noise

ratio in decibels, yi is the response value for the ith experiment, “i” is the
experiment number and n is the number of tests in each group.

Linear normalization for surface roughness, tool wear, roundness,

temperature, power consumption, and material removal rate was performed to
avoid the effect of using different units. It is in the range between zero to one
which is called GREY relational generating Surface roughness, roundness, tool
wear temperature and power consumption which are the smaller, the better ,
performance characteristics are normalized by Equation (4.3).

(4.3)

The material removal rate is higher the better

performance characteristic is normalized as follows

xi(o) (k) − min xi(o)(k)

xi∗(k) = (4.4)
max xi(o)(k) − min xi(o) (k)

where, xi (0) (k) Response variable

45
 Max xi (0) (k) Maximum value of response variable4

Min xi (0) (k) Minimum value of response variable

Step 2: Determination of deviation sequences, Δ0i(k)

The deviation sequence, Δ0i(k) is calculated by the absolute

difference between the reference sequence x0*(k) and the comparability
sequence xi*(k) after normalization. It is determined

(4.5)

where x0 * (k) Reference sequence

xi* (k) Comparability sequence

Step 3: Calculation of GREY Relational Coefficient (GRC)

GRC is used to expresses the relationship between the ideal (best) and
actual normalized S/N ratio. If two sequences agree at all points, then their
GREY relational coefficient is 1. The grey relational coefficient as

(4.6)

Step 4: Determination of weighted GREY relational grade (GRG)

Weights given to individual GRG. The weighted GREY relational

grade calculated by Equation (4.7).

46
 (4.7)

The weights W1, W2, W3, W4, W5,and W6given to various responses based on
the experience of the person and previous data

. Step 5: Determination of optimal parameters

From the response table for the GREY relational grade, the optimal
parameter level was found. The significance of each parameter about the GREY
relational grade to be checked by using analysis of variance.

4.4 RESPONSE SURFACE METHODOLOGY

RSM is a collection of mathematical methods to relate a response variable to the

independent ones in an experiment. So as a result, RSM is strictly related to
DOE.The mathematical model used for the approximation of experimental data
in the experimental domain is called “response surface”or “metal model”.This
method takes the advantage of representing a model to estimate the data over
the design space as well as optimization according to the desired criteria.

4.5 CONFIRMATION EXPERIMENT

A confirmation test is carried to check the responses after obtaining

optimum conditions. To predict and to verify the improvement of response
variables using an optimal combination, the estimated weighted GREY
relational grade calculated by Equation (4.8).

47
 q
γ̂ = γm + ∑ (γ̅ − γm) (4.8)
i=1

Ƴm is the total mean of weighted GRG

4.6 SUMMARY

In this chapter stepwise procedure of Taguchi based GREY relational

analysis is explained in detail. GREY relational grade is used for conversion of
optimization problem from a multi-objective to a single-objective. In GRA,
Weightage given to individual response variable is based on experience of
researcher. Weighted GREY relational grade is calculated based on weightage
of response variable. Response surface methodalogy is used to calculate the
weightage of response variable mathematically.

48
 CHAPTER 5

EXPERIMENTAL PROCEDURE,RESULT AND DATA

ANALYSIS

5.1 EXPERIMENTAL PROCRDURE

A scientific approach to plan the experiments is a necessity for efficient

conduct of experiments. By the statistical design of experiments the process of
planning the experiment is carried out, so that appropriate data will be collected
and analysed by statistical methods resulting in valid and objective conclusions.
When the problem involves data that are subjected to experimental error,
statistical methodology is the only objective approach to analysis. Thus, there
are two aspects of an experimental problem: the design of the experiments and
the statistical analysis of the data. These two points are closely related since the
method of analysis depends directly on the design of experiments employed.
The advantages of design of experiments are as follows:

 Numbers of trials is significantly reduced.

 Important decision variables which control and improve the performance of
the product or the process can be identified.
 Optimal setting of the parameters can be found out.
 Qualitative estimation of parameters can be made. Experimental error can be
estimated.
 Inference regarding the effect of parameters on the characteristics of the
process can be made.

In the present work, the Taguchi’s method, used to plan the experiments and
subsequent analysis of the data collected. The above chapter to prepare the DOE
it helps to experimental procedure.

49
5.2 BASED ON THE TAGUCHI METHOD

By using the Taguchi L9 orthogonal array to form experiment in the

given input parameter with their levels. Taguchi recommends orthogonal array
(OA) for laying out of experiments. To design an experiment is to select the
most suitable OA and to assign the parameters and interactions of interest to the
appropriate columns. The array forces all experimenters to design almost
identical experiments.

Table 5.1 Experimental Design

Experiment Servo voltage Pulse on time Pulse off time Wire feed
No. (µs) (µs) (m/min)
1 15 108 60 1
2 15 112 58 2
3 15 114 56 3
4 20 108 58 3
5 20 112 56 1
6 20 114 60 2
7 25 108 56 2
8 25 112 60 3
9 25 114 58 1

5.3 MACHINING IN WEDM

Based on the Taguchi method the experiments are conducted on the

Incoloy 800 to machine the given size. The image shows before machining and
after machining.
50
 Fig.no. 5.1 Before Machining

Fig.no. 5.2 After Machining

5.4CALCULATIONS

5.4.1 Kerf

b = dw + 2s

where,

b = kerf

dw = wire diameter

s = gap between the tool and work piece

For 1st specimen

51
 Wire diameter + job +2s = cutting size

0.25 + 3.708 + 2s = 4

2s = 0.042 mm

KERF (b) = wire diameter + 2s

= 0.25 + 0.042

KERF = 0.292 mm

For 2nd specimen,

Wire diameter + job + 2s = 4

0.25 + 3.713 + 2s = 4

2s = 0.037 mm

KERF = 0.287 mm

Similarly we calculated the kerf width value by this method and the readings
and the values are tabulated.

5.4.2Material removalrate

MRR = Vf * h * b
Here,

Vf = Wire feed in m/min

h = height or thickness of

the work piece b = Kerf

width

For the 1st specimen,

Vf = 1 m/min, h = 16 mm
52
 b = 0.292 mm.

MRR = Vf * h * b

= 1 * 16 * 0.292

= 4.672 mm3 / min.

For the 2nd specimen,

Vf = 2 m/min, h = 16 mm,

b = 0.287 mm.

MRR = Vf * h * b

= 2 * 16 * 0.287

= 9.184 mm3 / min.

Similarly calculated the MRR value for the 9 experiments and tabulated them.

5.4.3 Tool wear measurement

The tool wear rate is another important one its calculated by the use
of digital micro meter for calculated the diameter of the wire after machining.
Tool wear rate = {standard dia of wire}-{diameter of wire after machining}
Tool wear rate % = (tool wear / std diameter of wire) * 100
Tool wear rate = std dia of wire – dia after machining For 1stexperiment,
Here, standard diameter of wire = 0.25mm
Diameter after machining = 0.241mm.
Tool wear rate = standard diameter of wire – diameter after machining
= 0.25 – 0.241
= 0.009mm
Wear rate in % = (wear rate / original diameter of wire) *100
= (0.009 / 0.25) * 100
= 3.6%

53
For 2nd experiment,
Here, original diameter of wire = 0.25mm Diameter after machining = 0.249mm
Wear rate = original dia of wire -dia after machining
= 0.25 – 0.249
= 0.001mm
Wear rate in % = 0.4%.
The wear rate is calculated all the nine experiments and tabulated them.

Table 5.2 Experimental results

INPUT PARAMETERS OUTPUT PARAMETERS

S.no Pulse Pulse Wire Servo MRR Kerf Tool

on off Feed Voltage (mm^3/min) (min) Wear
time Time (m/min) rate
(µs) (µs) (mm)

1 108 60 1 15 6.42 0.321 0.004

2 112 58 2 15 13.13 0.328 0.005

3 114 56 3 15 19.56 0.326 0.003

4 108 58 3 20 12.56 0.314 0.003

5 112 56 1 20 19.32 0.322 0.006

6 114 60 2 20 6.74 0.337 0.004

7 108 56 2 25 20.04 0.334 0.005

8 112 60 3 25 6.64 0.332 0.002

9 114 58 1 25 13.68 0.342 0.005

54
It is the first step in the grey relational analysis; a normalization of the S/N ratio
is performed to prepare raw data for the analysis where the original sequence is
transferred to a comparable sequence. Linear normalization is usually required
since the range and unit in one data sequence may differ from the others. A
linear normalization of the S/N ratio in the range between zero and unity is also
called as the grey relational generation [4]. The “smaller-the-better” [17] is a
characteristic of the original sequence, and it is used to compare levels here in
the GRA. Then, the original sequence should be normalized as follows:

xi (k) = maxxi(0)(k) - xi(0)(k)

maxxi(0)(k) - minxi(0)(k) (5.1)

Determination of deviation sequences, Δ0i(k) The deviation sequence, Δ0i(k)

is the absolute difference between the reference sequence x0*(k) and the
comparability sequence xi*(k) after normalization.

Δ0i(k) = x0*(k) - xi*(k) (5.2)

Calculation of grey relational coefficient (GRC) GRC for all the sequences
expresses the relationship between the ideal (best) and actual normalized S/N
ratio. If the two sequences agree at all points, then their grey relational
coefficient is 1. The grey relational coefficient ℽ(x0(k),xi(k)) can be expressed
by

ℽ(x0(k),xi(k)) = Δ min + ζ Δmax

𝚫0i(k) + ζ Δmax (5.3)

55
Table 5.3 The data for 9 comparability sequences

Experimental run MRR Kerf Tool wear

1 0 0.75 0.5

2 0.4926 0.5 0.75

3 0.9647 0.5714 0.25

4 0.4508 1 0.25

5 0.9471 0.7128 1

6 0.0234 0.1785 0.5

7 1 0.2857 0.75

8 0.0161 0.3571 0

9 0.5330 0 0.75

Determination of weighted grey relational grade (GRG) The overall evaluation

of the multiple performance characteristics is based on the grey relational grade.
The grey relational grade [4] is an average sum of the grey relational
coefficients which is defined as follows

ℽ(x0 , xi ) = 𝑚1 𝑚
𝑖=1 ℽ(x0(k),xi(k)) (5.4)

where ℽ(x0 , xi ) is the grey relational grade for the jth experiment and m the
number of performance characteristics. Furthermore, based on the influence of
the quality characteristics on the overall process performance, the weights are
given to the individual GRGs, and theresultant GRG is termed as weighted grey
relational grade as follows

56
 ℽw (x0 , xi ) = 𝑚1 𝑚
ℽ(x0(k),xi(k))
𝑘=1 𝑤 1 (

+ w2 (ℽ(x0(k),xi(k))

+ w3 (ℽ(x0(k),xi(k))) (5.5)

where w1, w2, w3 are the weights associated with the individual quality
characteristics. The weighted grey relational grade γw(x0, xi) represents the level
of correlation between the reference sequence and the comparability sequence.
If the two sequences agree at all points, then their grey relational coefficient is 1
everywhere and therefore, their grey relational grade is equal to 1. In view of
this, the relational grade of two comparing sequences can be quantified by the
mean value of their grey relational coefficients and the grey relational grade.
The grey relational grade also indicates the degree of influence that a
comparability sequence could exert over the reference sequence. Therefore, if a
particular comparability sequence is more important than the other
comparability sequences to the reference sequence, then the grey relational
grade for that comparability sequence and reference sequence will be higher
than other grey relational grade.

Determination of optimum parameters The weighted grey relational grade

calculated for each sequence is taken as a response for the further analysis. The
larger-the-better quality characteristic was used for analyzing the GRG, since a
larger value indicates the better performance of the process. The quality
characteristics used is given. The number of repeated test is one, since only one
relational grade was acquired in each group for this particular calculation of
S/N. The grey relational grade is obtained.

57
Table 5.4 The calculated grey relational coefficient and weighted grey
relational grade for 9 comparability sequences.

Grey relational coefficient Weighted

Experimental grey
run MRR Kerf Tool wear relational
grade
1 0 0.225 0.2 0.1416
2 0.1477 0.15 0.3 0.1992
3 0.2894 0.1714 0.1 0.1869
4 0.1352 0.3 0.1 0.1784
5 0.2841 0.2138 0.4 0.2993
6 0.0704 0.0535 0.2 0.1079
7 0.3 0.0857 0.3 0.2285
8 0.0485 0.1071 0 0.0518
9 0.1599 0 0.3 0.1533

Table 5.5 Weighted grey relational grade and its order

Experimental number Weighted grey Order
relational grade
1 0.1416 7
2 0.1992 3
3 0.1869 4
4 0.1784 5
5 0.2993 1
6 0.1079 8
7 0.2285 2
8 0.0518 9
9 0.1533 6

Variance(ANOVA) and the analysis of means (AOM). ANOVA is used to

reveal the level of significance of influence of factor(s) or interaction of factors
on a particular response. This is accomplished by separating the total variability
of the grey relational grades, which is measured by the sum of the squared
deviations from the total mean of the grey relational grade, into contributions by
each turning process parameters and the error. The response table of Taguchi
method was employed here to calculate the average grey relational grade for

58
each factor level. In this, the grouping of the grey relational grades was done
initially by the factor level for each column in the orthogonal array and then by
averaging them.

Table 5.6 Response table for weighted grey relational grade

Levels MRR Kerf Tool wear

1 0.1759 0.1828 0.1004
2 0.1952 0.1834 0.1769
3 0.1445 0.1493 0.1759
Max-min 0.0506 0.0340 0.0765
Ranking 2 3 1

Prediction of grey relational grade under optimum parameters After evaluating

the optimal parameter settings, the next step is to predict and verify the
improvement of quality characteristics using the optimal parametric
combination. The estimated grey relational grade bg using the optimal level of
the machining parameters can be calculated where γm is the total mean grey
relational grade, γi is the mean grey relational grade at the optimal level, and o
is the number of the main design parameters that affect the quality
characteristics. The predicted or estimated grey relational grade (optimal) is
equal to the mean grey relational grade plus the summation of the difference
between the overall mean grey relational grade and the mean grey relational
grade for each of the factors at optimal level.

5.5 RESULT AND DATA ANALYSIS

The experiments are carried out using L9 orthogonal matrix and the results are
presented in Table 3. The most important measurement in RESPONSE
SURFACE METHOD is used to analyze experimental results by normalized
assessment. In this investigation, level of the maximum value of normalized
assessment is used to obtain optimum machining parameters combinations.
Table 4 shows data of normalized assessment value. In this study, two
categories of output parameters are considered (i.e.) maximization and
minimiz5ation objectives. To achieve optimum conditions, minimization
characteristics for kerf, tool wear rate and maximization characteristics for
MRR are considered. The weight factors are involved in solving multi-objective
59
optimization. These weights can be assigned by engineers’ experiences and
importance of output parameters. Entropy measurement is also used to estimate
the weight factors of each objective function. The calculated weights of the
MRR, kerf and tool wear rate values are found to be 0.332479898, 0.329485901
and 0.3380342 respectively. The estimated weight factor of each output
parameters are roughly equivalent. The similar types of results are obtained by
several researchers during weight determination in optimization of process
parameters in turning, EDM and laser process.

Based on the high value of normalized assessment, pulse on time is 109µs, pulse
off time is 58µs, wire feed is 3 m/min and servo voltage is 30 volts are the
optimum machining parameters. The optimum combination of machining
parameters Ton-2, Toff -2, WF-3, and SV-1is obtained using the combined
RESPONSE SURFACE METHOD and entropy method in machining
operation. Therefore, the above optimum machining parameters are considered
for validation analysis. The experimental result showed that responses in
machining process can be improved efficient. It81 is noticed that, when
compared with other MCDM methods (such as Analytic Hierarchy
Process(AHP), Technique for Order Preference by Similarity to Ideal Solution
(TOPSIS), (VIKOR), GRA etc.), the RESPONSE SURFACE METHOD is very
simple to understand and easy to implement. This method is based only on
simple ratio analysis and lesser mathematical computations, which may be quite
useful and helpful to the decision makers who may not have a strong
background in mathematics. Also, RESPONSE SURFACE METHOD involves
less computational time due to its minimum computational steps. Another
important advantage of this method is that its computational steps are not
affected by the introduction of any extra parameter (for example v in VIKOR
and xi in GRA methods) as it happens in other multiobjective optimization
techniques. For this purpose, the RESPONSE SURFACE METHOD is highly
desirable for various decision-making problems.

60
5.6 METHOD

Factor coding (-1, 0, +1)

Factor Information
Factor Type Levels Values
C1 Fixed 3 1, 2, 3
C2 Fixed 3 1, 2, 3
C3 Fixed 3 1, 2, 3
C4 Fixed 3 1, 2, 3

Analysis of Variance
F- P-
Source DF Adj SS Adj MS Value Value
C1 2 0.003923 0.001962 * *
C2 2 0.002281 0.001140 * *
C3 2 0.028600 0.014300 * *
C4 2 0.005427 0.002713 * *
Error 0 * *
Total 8 0.040231

Model Summary
S R-sq R-sq(adj) R-sq(pred)

* 100.00% * *

61
Coefficients
SE T- P-
Term Coef Coef Value Value VIF
Constant 0.1719 * * *
C1
1 0.004022 * * * 1.33
2 0.02332 * * * 1.33
C2
1 0.01096 * * * 1.33
2 0.01156 * * * 1.33
C3
1 -0.07144 * * * 1.33
2 0.005089 * * * 1.33
C4
1 0.02619 * * * 1.33
2 0.006656 * * * 1.33

Regression Equation
C6 = 0.1719 + 0.004022 C1_1 + 0.02332 C1_2 - 0.02734 C1_3
+ 0.01096 C2_1 + 0.01156 C2_2
- 0.02251 C2_3 - 0.07144 C3_1 + 0.005089 C3_2
+ 0.06636 C3_3 + 0.02619 C4_1
+ 0.006656 C4_2 - 0.03284 C4_3

62
Fig.no 5.3

Fig.no 5.4

63
Fig.no5.5

Fig.no 5.6

64
Fig.no 5.7

Fig.no 5.8

65
Fig.no 5.9

Fig.no 5.10

66
PHOTOGRAPHY

67
68
69
70
71
72
73
 CHAPTER 6

CONCLUSION

In this experimental study, the combined Response surface method and Grey
relation method is applied for the estimation of optimum machining parameters
are to minimize the Kerf, tool wear rate and maximize MRR. The conclusions
drawn from thisstudy are as follows:

 Combined Response surface method and Grey relation methodis

employed to select the optimum machining parameters in machining of
Incoloy 800 in the wire cut electric discharge machining.

 The high value of normalized assessment demonstrate the pulse on time

109 µs, pulse off time 58 µs, wire feed rate of 3m/min, servo voltage of
30 volts are essential parameters to minimize kerf, tool wear rate and
maximize MRR simultaneously. Grey relation analysis method is also
employed to find the relative importance of MRR, kerf and tool wear rate.
The weight ratios are found to be 0.332479898, 0.329485901 and
0.3380342 respectively.

 The optimum results are adopted in validation study and the results based
on machining process responses can be effectively improved.

 The proposed method can be used for simultaneous optimization of other

machining processes with different process parameters.

74
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