Response Surface Methodology Approach to Process Modeling and Optimization of Powder Mized Electrical Discharge Machining (PMEDM)
In this research, an attempt has been made to model and optimize the process parameters involved in powder mixed electrical discharge machining (PMEDM). Aluminum oxide (Al2O3) fine abrasive powders having the particle concentration and size of 2.5-2.8 gr/lit and 45-50 μm, respectively, were added into the kerosene dielectric liquid of a die-sinking electrical discharge machine. The experiments were carried out in planing mode on a specially designed experimental set up developed in laboratory. BD3 heat treated alloy steel and commercial copper were used as work piece and tool electrode materials, respectively. Response surface methodology, employing a face-centered central composite design (CCD), has been used to plan and analyze the experiments. Based on the preliminary and screening tests as well as the working characteristics of EDM machine, discharge current (I), pulse period (T: Ton +Toff), and source voltage (V) were selected as the independent input variables to evaluate the process performance in terms of material removal rate (MRR) and surface roughness (Ra). Suitable mathematical models for the response outputs were obtained using the analysis of variance (ANOVA), in which significant terms (main effects, two factor interactions, and pure quadratic terms) were chosen according to their p-values less than 0.05 (95% of confidence interval). Having established the process model, a search optimization procedure, based on the use of desirability functions, optimizes the process performance in each machining regime of finishing (Ra≤3 μm), semi-finishing (3 μm≤Ra≤4.5 μm), and roughing (Ra≥4.5 μm). The results are sets of optimum points which make the MRr as high as possible and keep the Ra and all machining parameters in their specified ranges, simultaneously. All the analysis and simulations were done using the design of experiments module of the Minitab Statistical Software, Release 15. Finally, the obtained optimization results were also verified experimentally, showing good agreement with theoretical expectations and simulation results.
Powder mized EDM (PMEDM) Response surface method (RSM) ANOVA Modeling Optimization
S. Assarzadeh M. Ghoreishi M. Shariyyat
Specific Machinings Laboratory (S. M. L.), Department of Mechanical Engineering, K. N. Toosi University of Technology, P.O. Box: 19395-1999, Tehran, Iran
国际会议
The 16th International Symposium on Electromachining(第16届国际电加工会议)
上海
英文
181-186
2010-04-19（万方平台首次上网日期，不代表论文的发表时间）