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Influence of optimization techniques and nano surface coating materials on microstructure of iron-nickel-chromium alloy using wire EDM process

R. Selvabharathi
R. Selvabharathi
, 
R. Ganapathy Srinivasan
R. Ganapathy Srinivasan
 et 
S. Palani
S. Palani
   | 09 août 2021
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Publié en ligne: 09 août 2021
Pages: 152 - 165
Reçu: 10 févr. 2021
Accepté: 14 mars 2021
DOI: https://doi.org/10.2478/msp-2021-0003
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© 2021 R. Selvabharathi et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Cause and effect diagram for performance characteristics in WEDM
Cause and effect diagram for performance characteristics in WEDM

Fig. 2

Flow chart diagram of optimization techniques
Flow chart diagram of optimization techniques

Fig. 3

BPNN model used for process parameter analysis and optimization techniques
BPNN model used for process parameter analysis and optimization techniques

Fig. 4

Adaptive neuro-fuzzy interference system (ANFIS)
Adaptive neuro-fuzzy interference system (ANFIS)

Fig. 5

(a) Plot diagram of material removal rate; (b) Plot diagram of surface roughness SR (μm)
(a) Plot diagram of material removal rate; (b) Plot diagram of surface roughness SR (μm)

Fig. 6

The best fitness value estimated by BPNN model of (a) Material removal rate (b) Surface roughness SR (μm)
The best fitness value estimated by BPNN model of (a) Material removal rate (b) Surface roughness SR (μm)

Fig. 7

Plot diagram of material removal rate of ANFIS model
Plot diagram of material removal rate of ANFIS model

Fig. 8

Plot diagram of surface roughness of ANFIS model
Plot diagram of surface roughness of ANFIS model

Fig. 9

SEM analysis a) Alloy 20 materials b) Coating materials c) Hybrid treated alloy 20 microstructure after machining
SEM analysis a) Alloy 20 materials b) Coating materials c) Hybrid treated alloy 20 microstructure after machining

EDM process parameter of Taguchi L27 orthogonal array

Experimental trials Factor
A B C
1 1 1 1
2 1 1 2
3 1 1 3
4 1 2 1
5 1 2 2
6 1 2 3
7 1 3 1
8 1 3 2
9 1 3 3
10 2 1 1
11 2 1 2
12 2 1 3
13 2 2 1
14 2 2 2
15 2 2 3
16 2 3 1
17 2 3 2
18 2 3 3
19 3 1 1
20 3 1 2
21 3 1 3
22 3 2 1
23 3 2 2
24 3 2 3
25 3 3 1
26 3 3 2
27 3 3 3

Cumulative experimental data of EDM process.

SI.NO Pulse on time T ON (μ sec) Pulse off time T OFF (μ sec) Wire feed WF (m/min) Material removal rate MRR (mm/min) Surface roughness SR (μm)
1 106 40 4 0.68 1.385
2 106 40 8 0.71 1.255
3 106 40 12 0.505 1.175
4 106 50 8 0.48 1.35
5 106 50 12 0.405 1.265
6 106 50 4 0.2 1.105
7 106 60 12 0.315 1.35
8 106 60 4 0.165 1.14
9 106 60 8 0.165 1.08
10 116 40 12 2.405 2.57
11 116 40 4 2.205 2.39
12 116 40 8 0.75 1.435
13 116 50 4 1.54 2.525
14 116 50 8 0.58 1.38
15 116 50 12 0.66 1.72
16 116 60 8 0.47 1.63
17 116 60 12 0.625 1.85
18 116 60 4 0.5 1.625
19 126 40 8 3.4 2.9
20 126 40 12 1.26 1.85
21 126 40 4 2.2 2.66
22 126 50 12 0.91 2.08
23 126 50 4 1.66 2.635
24 126 50 8 1.54 2.445
25 126 60 4 1.34 2.855
26 126 60 8 1.345 2.56
27 126 60 12 0.29 1.295

(a) 1st EDM Process parameter of alloy 20 materials; (b) 2nd EDM Process parameter of alloy 20 materials

No MRR (mm/min) SR (μm)
EOP BPOP ERROR EOP BPOP ERROR
1 0.68 0.5643 11.57 1.385 1.3627 2.23
2 0.71 0.7451 −3.51 1.255 1.2712 −1.62
4 0.48 0.4921 −1.21 1.35 1.3215 2.85
10 2.405 2.4184 −1.34 2.57 2.3954 17.46
14 0.58 0.5683 1.17 1.38 1.4725 −9.25
17 0.625 1.0514 −42.64 1.85 2.3891 −53.91
22 0.91 0.9244 −1.44 2.08 2.0176 6.24
23 1.66 1.7587 −9.87 2.635 2.7871 −15.21
25 1.34 1.3572 −1.72 2.855 2.8142 4.08

Regression ratio of material removal rate

Source DF Adj SS Adj MS F-Value P-Value
Regression 3 13.1260 4.3753 21.32 0.000
Pulse on time t on (μ sec) 1 7.8095 7.8095 38.06 0.450
Pulse off time t on (μ sec) 1 5.0545 5.0545 24.63 0.300
Wire feed 1 0.2620 0.2620 1.28 0.250
Error 23 4.7195 0.2052
Total 26 17.8454

Results of BPNN-ANFIS optimization

Sl. No. Input parameters Output parameters
Pulse on time (μ sec) Pulse off time (μ sec) Wire feed (m/min) Optimal value (mm) Machining performance
1. 110 80 10 0.184 Material removal rate
2. 106 60 10 1.95 Surface roughness

EDM process parameters and error of confirmation experiment

Input parameters Output parameters
Pulse on time (μ sec) Pulse off time (μ sec) Wire feed (m/min) Material removal rate (mm/min) Surface roughness (μm)
Experiment predicted by 106 60 8 0.155 1.08
BPNN-ANFIS model 105.7 59 8 0.1675 1.1182
Error % −1.5 −3.5

BPNN parameters and interlayer details

Name Number No. MRR SR
parameter. Show 50 1st 9 9
Maximum parameter. Epochs 1000
Number of input parameter 3 2nd 8 10
Number of output parameter 1

Process parameters employed for EDM

Parameter Unit Factor Level
1 2 3
Pulse on time (μ sec) A 106 116 126
Pulse off time (μ sec) B 40 50 60
Wire feed (m/min) C 4 8 12

Regression ratio of surface roughness SR (μm)

Source DF Adj SS Adj MS F-Value P-Value
Regression 3 1.96406 0.65469 16.14 0.000
Pulse on time t on (μ sec) 1 1.76964 1.76964 43.62 0.420
Pulse off time t on (μ sec) 1 0.08050 0.08050 1.98 0.470
Wire feed 1 0.11392 0.11392 2.81 0.210
Error 23 0.93314 0.04057
Total 26 2.89719

Chemical composition of alloy 20 (in wt%)

Si S P Mn C Nb Mo Cu Cr Fe Ni
1 0.035 0.045 2 0.07 1 3 4 21 29.8 38
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