Experimental Investigation, Predictive Modeling, Parametric Optimization and Cost Analysis in Electrical Discharge Machi
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ORIGINAL PAPER
Experimental Investigation, Predictive Modeling, Parametric Optimization and Cost Analysis in Electrical Discharge Machining of Al-SiC Metal Matrix Composite Subhashree Naik 1 & Sudhansu Ranjan Das 1 & Debabrata Dhupal 1 Received: 3 December 2019 / Accepted: 13 April 2020 # Springer Nature B.V. 2020
Abstract This experimental investigation deals with electrical discharge machining of Al-SiC metal matrix composite using a brass electrode to analyze the three major technological response characteristics concerning surface roughness, overcut, and material removal rate. Forty-six sets of experimental trials are conducted by considering five cutting parameters (discharge current, gap voltage, pulse-on-time, pulse-off-time and flushing pressure) based on Box-Behnken’s design of experiments (BBDOEs). Additionally, response surface methodology (RSM), analysis of variance (ANOVA), and statistical technique (here, desirability function approach) followed by computational approach (here, genetic algorithm) are employed respectively for experimental investigation, predictive modeling, and multi-response optimization. Thereafter, the effectiveness of proposed two (RSM, GA) multi-objective optimization techniques are evaluated by the confirmation test. Subsequently, the best optimal solution is employed for economic analysis. Additionally, the effects of discharge current on influencing various response features have also been studied. Finally, an approach has been proposed for sustainability assessment, taking into consideration of the environmental impact and the dielectric consumption created by the electrical discharge machining process. The result shows that discharge current has the significant contribution (72.23% for MRR, 40.56% for Ra, 34.01% in case of OC) in improvement of material removal rate, degradation of surface finish as well as the dimensional deviation of hole diameter, especially overcut. The proposed vegetable oil-based dielectric fluid is biodegradable, eco-friendly, and thus leading sustainable manufacturing. Keywords EDM . Al-SiC MMC . Surface roughness . Overcut . MRR . Optimization . Cost analysis
1 Introduction Science and technology have been advancing to an infinite extent in search of newer materials and alloys with high hardness, strength, and less weight. Day-by-day, metal matrix composites (MMC) have increasingly widened their use in manufacturing sectors like aerospace, defense, manufacturing, automobile, electronic, and nuclear industries. These materials are extensively used in different industrial applications to attain high performances due to their favorable characteristics
* Sudhansu Ranjan Das [email protected] 1
Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Odisha 768018, India
such as lightweight, more excellent resistance to wear, high specific strength and high-temperature resistance than conventional materials [1]. Lightweight materials are mechanically consistent with lesser manufacturing costs. In the viewpoint
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