A

PROJECT REPORT
ON
OPTIMIZATION OF PROCESS PARAMETERS OF ROTARY EDM BY
USING GENETIC ALGORITHM
Submitted in the partial fulfillment of the requirements for the award of the
degree
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
ULHAS N KANEKAR (20080128)
MAYUR R BARAHATE (20080103)

UNDER THE GUIDANCE OF

Dr. R. S. PAWADE

DEPARTMENT OF MECHANICAL ENGINEERING

DR. BABASAHEB AMBEDKAR TECHNOLOGICAL UNIVERSITY
LONERE 402103, RAIGAD (M.S.)
2011 - 2012

Page 1

APPROVAL SHEET

A project report entitled OPTIMIZATION OF PROCESS PARAMETER

OF ROTARY EDM BY USING GENETIC ALGORITHM by ULHAS
KANEKAR, MAYUR BARAHATE for the partial fulfillment of the award of the
Degree of Bachelor of Technology in Mechanical Engineering of Dr. Babasaheb
Ambedkar Technological University, Lonere.

Dr. P. K Brahmankar

Dr. R. S. PAWADE
GUIDE

Department of Mechanical Engineering

Dr. Babasaheb Ambedkar
Technological University,
Lonere - 402103

Examiners
1.
2.

Page 2

ACKNOWLEGEMENT
A project work of this magnitude requires a large effort, which in many parts is
contributed by our colleagues in various forms. It is our pleasant duty to acknowledge
such contributions.
We express our profound sense of gratitude to Dr. R. S. Pawade, our project
guide

of

Mechanical

Engineering

Department,

Dr.

Babasaheb

Ambedkar

Technological University, Lonere, for their systematic guidance, valuable advice and
the constant encouragement throughout the project.
We also wish to express our sincere thanks to Dr. P. K. Brahmankar, Head,
Mechanical Engineering Department, Dr. Babasaheb Ambedkar Technological
University, Lonere for his valuable and motivating support. We are also thankful to
departmental staff members for their support. And last but not the least, to our friends
whose contribution we just cant express.

ULHAS N KANEKAR (20080128)

MAYUR R BARAHATE (20080103)

Page 3

ABSTRACT

The project work deals with determining the optimum condition for the process
parameters to minimize the surface roughness, electrode wear rate and maximize
material removal rate of rotary electrical discharge machine. This condition is
achieved by firstly experimentation in actual machining condition at different levels
of input value. Secondly from these values, the optimum values of output are obtained
by multi objective genetic algorithm model in matlab software. Then an experiment is
done from optimum input values and these results are then campared with result from
matlab algorithm.

Page 4

LIST OF FIGURES
FIGURE

PAGE

TITLE OF FIGURE

NO.

1.1

NO.

EDM with (a) stationary electrode, (b) rotating electrode, (c) rotating

electrode with orbital motion.

1.2

Sketch of equipment

1.3

Crossover

13

1.4

Mutation

13

1.5

Mathematical modelling

14

2.1

Generation of a square with a sharp corner using a modified RT

17

2.2

The material removal depth vs. the rpm of the RDE electrode with

18

the discharge current as a parameter

2.3

Rotations of rotary EDM

18

2.4

Vibratory, rotary, vibratory & rotary

19

2.5

Comparison between the traditional EDM and the electrode orbiting

19

EDM: (a) die-sinking machining without orbiting; (b) dimensional

deviation of the cavity arising from the orbital motion
2.6

Effect of vibration

20

2.7

Feed rate mechanism in the EDM processes. (a) Without machining,

21

feed speed 50 mm/s, (b) first second, 5 mm/s feed rate 50 mm/s and
(c) during machining, feed rate 5 mm/s
2.8

Rotary attachment with special purpose motor

23

2.9

Rotary attachments with outer brushes

23

2.10

Sketch of equipment

24

2.11

Discharge mechanisms: experiment equipment

24

2.12

A newly developed electrode tool of B-EDM

26

2.13

Schematic experimental surface profile of Al 2 O 3 /6061 composite for

27

the B-EDM process.

3.1

Electrical discharge machines

33

3.2

Developed low cost rotary attachment

34

Page 5

3.3

Trimos Vertical

34

3.4

Precision weighing balances

34

3.5

Tentative schematic of rotary attachment

35

3.6

Electrically conducting plate

36

3.7

Insulating plate

36

3.8

Belt and pulley

37

3.9

Developed low cost Rotary Attachment

38

4.1

Main effect plot and pareto diagram of MRR

44

4.2

Main effect plot and pareto diagram of EWR

45

4.3

Main Effect Plot and Pareto diagram of SR

46

4.4

Flowchart of GA for optimization

48

Page 6

LIST OF TABLES

TABLE NO.

TITLE OF TABLE

FIGURE NO.

3.1

Control factors and their levels for experiment

31

3.2

Properties of SKD11

32

3.3

Technical specifications of EDM

33

3.4

Experimental design matrices

39

4.1

Experimental results

42

4.2

Optimal set of process parameters with its respective MRR,

53

EWR and SR

4.3

Optimal Set of process parameters for minimization of MRR,

54

EWR and SR (predicted results)

4.4

Optimal Set of process parameters for minimization of SR and 54

EWR, and maximization of MRR (experimental results)

4.5

Comparison between Target and Predicted Optimal values

Page 7

54

CONTENTS
Page
No.
i

Title Page
Approval Sheet

ii

Acknowledgement

iii

Abstract

iv

List of Figures

List of tables
Chapter

vii

INTRODUCTION

1.1 Background

1.2 Motivation and objectives of work

1.3 Rotary EDM

1.3.1 Working principle

1.4 Optimization

Chapter 2

1.4.1 Various methods

1.4.2 Where GA method stands

1.5 Advantages of optimization process in machining

1.6 Genetic algorithm

10

1.6.1 Initialization

11

1.6.2 Evaluation

11

1.6.3 Reproduction

12

1.6.4 Selection

12

1.6.5 Crossover

12

1.6.6 Mutation

13

1.7 Mathematical model approach

14

LITERATURE SURVEY

15

2.1 Process principle

15

2.2 Effect of electrical parameters

16

2.3 Effect of non-electrical parameters

16

2.3.1 Effect of flushing condition

16

2.3.2 Effect of electrode rotation

17

2.3.3 Effect of ultrasonic vibration

20

Page 8

2.3.4 Effect of dielectric fluid

2.4 Rotary attachment

22

2.4.1 Rotating a workpiece

22

2.4.2 Rotating the electrode

22

2.4.3 Different rotary attachments to EDM

22

2.5 Performance Measurement

Chapter 3

Chapter 4

21

25

2.5.1 Material removal rate

25

2.5.2 Tool wear rate

25

2.5.3 Surface roughness

26

2.6 GA optimization

27

EXPERIMENTAL WORK

30

3.1 Planning of experiment

30

3.1.1 Design of experiment

30

3.1.2 Workpiece material

31

3.2 Experimentation

32

3.2.1 Equipment

32

3.2.2 Rotary attachment

34

3.2.3 Experimental design matrix

38

3.2.4 Machining set-up

39

3.2.5 Measurement of responce

40

RESULT AND DISCUSSION

42

4.1 Regression equation

43

4.2 GA optimization

47

4.3 Optimization model

48

4.3.1 Decision variable

49

4.3.2 Objection function

49

4.3.3 Variable bound

49

4.4 GA implementation

49

4.5 Output from genetic algorithm

52

4.6 Confirmation and Validation of Optimal Settings of

53

Process Parameters

Page 9

Chapter 5

CONCLUDING REMARK

55

REFERENCES

56

Page
10

CHAPTER ONE

INTRODUCTION
1.1BACKGROUND
Metal erosion by spark discharges was first observed by Sir Joesh Pristeley in
1768. More than a hundred years were to elapse before some practical use of the
effect was made. Spark discharges became used increasingly for the disintegration of
various metals to produce colloidal solutions, and for the removal of broken taps,
drills and reamers.
Although the electric discharge machine (EDM) process is not affected by
material hardness and strength, it is a much slower process compared to other preprocesses. To increase its speed, a large electrical current discharge is normally used.
But, this will inevitably compromise the dimensional accuracy of the machined
product. The EDM process can be very unstable due to arcing, when too much debris
clogs the gap. Therefore, the question is how to develop an EDM process with the
capability of high speed machining, high accuracy and precision without any major
alteration to the EDM system. Experts are in constant pursuit of improving the
performance of EDM machining. In the past few years, the Taguchi method has
played an important role in the optimization of process parameters. However, many of
the studies have focused on static or single-quality characteristics such as smaller-isbetter, larger-is-better, and nominal-is-best and classified attributes. The application
of this method using functional quality provides solutions to all three aspects of
technologies, flexibility and reproducibility. To meet the challenges of a rapidly
changing world, the EDM technology must have the process capabilities of high
speed, high accuracy and precision, versatility and robustness. Hence, the purpose of
this study is an attempt to apply a robust technology development approach of GA
methods for optimizing the EDM machining process so as to achieve the above
goals[2].

1.2 MOTIVATION AND OBJECTIVES OF WORK

Electrical discharge machining (EDM) is a manufacturing process by which a tool cut
the required shape in to the work piece within a dielectric fluid. Short duration
Page
11

discharge is generated in a liquid dielectric gap, which separates tool and work piece.
The material is removed with the erosive effect of the electrical discharge in the EDM
processes a highly complex phenomenon to which scientific knowledge is incomplete
both at macroscopic as well as the microscopic level[1]. In the past 50 years, research
has been done to develop and improve different models of material removal from both
tool and work piece. The main cause for material removal from both of the electrodes
in EDM process is the temperature reached by the surface of both electrodes. The
material of both tool and work piece is removed. Its temperature is above the melting
temperature. This temperature at the surface of both electrodes is due to the thermal
energy which is generated in a discharge channel has a non-cylindrical shape
however, the assumption that the discharge channel has a cylindrical shape has been
done in order to simplify the model construction. The discharge channel is composed
of a gaseous mix surrounded by the fluid dielectric.
The basis of controlling the EDM process mostly relies on empirical methods
largely due to the stochastic nature of the sparking phenomenon involving both
electrical and non-electrical process parameters. The complicated interrelationship
between the different optimized process parameters is therefore a major factor
contributing to the overall machining efficiency[3].
The EDM process needs to be constantly revitalized to remain competitive in
providing an essential and valuable role in the tool room manufacturing of part with
difficult-to-machine materials and geometries.
In the case of MRR and EWR, it has been seen that the decrease in pulse on
time, decrease in electrode rotation and increase in peak current, increases both the
machining output, while investigation is carried out with rotary electrode. In the case
of SR, it has been seen that the increase in pulse on time, decrease in peak current and
decrease in electrode rotation, improves SR, while investigation is carried out with
rotary electrode (Chattopadhyay et al., 2008). With the above motivating conclusions
we have derived overall objectives.

1.3 ROTORY EDM

Different non-traditional machining techniques are increasingly employed to
manufacture different high quality industrial components. Among the non-traditional

Page
12

methods of machining processes, electrical discharge machining (EDM) has drawn a

great deal of attention because of its broad industrial applications including different
dies and tools. In this process material is removed by controlled erosion through a
series of electric sparks between the tool (electrode) and the work piece. The thermal
energy of the sparks leads to intense heat conditions on the work piece causing
melting and vaporizing of work piece material. Due to the high temperature of the
sparks, not only work material is melted and vaporized, but the electrode material is
also melted and vaporized, which is known as electrode wear (EW).

1.3.1 Working principle

Figure 1.1 EDM with (a) stationary electrode, (b) rotating electrode, (c) rotating
electrode with orbital motion[3].

Page
13

Figure 1.2 Sketch of equipment[3]

Electrical discharge machining makes use of high frequency pulse discharge
between the work piece and the electrode to produce the phenomenon of vaporization
and melting at the electric discharge point At the same time, the dielectric is heated
instantly to an extremely high temperature so that the temperature of a small portion
of the work piece material is heated above its melting point and it is then carried
away. In electric discharge machining the tool electrode dose not physically contact
the work piece, and almost non-loaded.
Electrical discharge machining (EDM) is a manufacturing process by which a
tool cut the required shape in to the work piece within a dielectric fluid. Short
duration discharge is generated in a liquid dielectric gap, which separates tool and
work piece.

1.4 OPTIMIZATION
Optimization algorithms are becoming increasingly popular in engineering
activities, primarily because of the availability and affordability of high-speed
computers. They are extensively used in those engineering problems where the
emphasis is on maximizing or minimizing of a certain goal. For example,
optimization algorithms are routinely used in aerospace design activities to minimize
the overall weight, simply because every element or component adds to the overall

Page
14

weight of the aircraft. Chemical engineers on the other hand are interested in
designing or operating a process plant for an optimum rate of production[4].

Mechanical engineers design mechanical components for the purpose of

achieving either a minimum manufacturing cost or maximum rate of production.
Production engineers are interested in designing optimum schedules of various
machining operations to minimize the idle time of machines and the overall
completion time. Civil engineers are involved in designing buildings, dams and other
structures in order to achieve a minimum overall cost or maximum safety or both.
Electronics engineers are interested in designing communication networks so as to
achieve minimum time for communication from one node to another. Thus, the
ultimate aim of the optimization is to improve an existing process that meets the given
requirements and satisfies all the restrictions/constraints placed on it. This is called
the optimum process. The system used for optimization is based on powerful artificial
intelligence called genetic algorithms (GA).

1.4.1 Various Methods

Traditional method
Traditionally, the selection of cutting conditions for metal cutting is left to the
machine operator. In such cases, the experience of the operator plays a major role, but
even for a skilled operator it is very difficult to attain the optimum values each time.
Machining parameters in metal drilling are cutting speed, feed rate and diameter of
cut .The setting of these parameters determines the quality characteristics of turned
parts.

Latest techniques
The latest techniques for optimization include fuzzy logic, scatter search
technique, genetic algorithm, Taguchi technique and response surface methodology.
a. Fuzzy logic
Fuzzy logic has great capability to capture human commonsense reasoning,
decision-making and other aspects of human cognition. Kosko(1997) shows that it

Page
15

overcomes the limitations of classic logical systems, which impose inherent

restrictions on representation of imprecise concepts. Vagueness in the coefficients and
constraints may be naturally modeled by fuzzy logic. Modeling by fuzzy logic opens
up a new way to optimize cutting conditions and also tool selection.

b. Scatter search technique (SS):

This technique originates from strategies for combining decision rules and
surrogate constraints. SS is completely generalized and problem-independent since it
has no restrictive assumptions about objective function, parameter set and constraint
set. It can be easily modified to optimize machining operation under various
economic criteria and numerous practical constraints. It can obtain near-optimal
solutions within reasonable execution time on PC. Potentially, it can be extended as
an on-line quality control strategy for optimizing machining parameters based on
signals from sensors. Chen & Chen (2003) have done extensive work on this
technique.

c. Taguchi technique:
Genichi Taguchi is a Japanese engineer who has been active in the improvement
of Japans industrial products and processes since the late 1940s. He has developed
both the philosophy and methodology for process or product quality improvement that
depends heavily on statistical concepts and tools, especially statistically designed
experiments. Many Japanese firms have achieved great success by applying his
methods. Taguchis major contribution has involve combining engineering and
statistical methods to achieve rapid improvements in cost and quality by optimizing
product design and manufacturing processes.
Taguchis ideas can be distilled into two fundamental concepts:
(a) Quality losses must be defined as deviations from targets, not conformance to
arbitrary specifications (Benton 1991).
(b) Achieving high system-quality levels economically requires quality to be designed
into the product. Quality is designed, not manufactured, into the product (Daetz 1987;
Taguchi
1989)

Page
16

d. Response surface methodology (RSM):

Experimentation and making inferences are the twin features of general scientific
methodology. Statistics as a scientific discipline is mainly designed to achieve these
objectives. Planning of experiments is particularly very useful in deriving clear and
accurate conclusions from the experimental observations, on the basis of which
inferences can be made in the best possible manner.
e. Genetic algorithm (GA)
These are the algorithms based on mechanics of natural selection and natural
genetics, which are more robust and more likely to locate global optimum. It is
because of this feature that GA goes through solution space starting from a group of
points and not from a single point. The cutting conditions are encoded as genes by
binary encoding to apply GA in optimization of machining parameters. A set of genes
is combined together to form chromosomes, used to perform the basic mechanisms in
GA, such as crossover and mutation[2].

Crossover is the operation to exchange some part of two chromosomes to generate

new offspring, which is important when exploring the whole search space rapidly.
Mutation is applied after crossover to provide a small randomness to the new
chromosomes. To evaluate each individual or chromosome, the encoded cutting
conditions are decoded from the chromosomes and are used to predict machining
performance measures. Fitness or objective function is a function needed in the
optimization process and selection of next generation in genetic algorithm. Optimum
results of cutting conditions are obtained by comparison of values of objective
functions among all individuals after a number of iterations. Besides weighting factors
and constraints, suitable parameters of GA are required to operate efficiently. GA
optimization methodology is based on machining performance predictions models
developed from a comprehensive system of theoretical analysis, experimental
database and numerical methods. The GA parameters along with relevant objective
functions and set of machining performance constraints are imposed on GA
optimization methodology to provide optimum cutting conditions.

Page
17

1.4.2 WHERE GA METHOD STANDS

As seen from the above description of the working principles of GAs, they are
radically different from most of the traditional optimization methods. However, the
fundamental differences are described as:

(i) Discretization Of Search Space

GA works with a string coding of variables instead of the variables. The
advantage of working with a coding of variables is that the coding discretizes the
search space; even though the function may be continuous function can be handled
with no extra cost. This allows GAs to be applied to a wide variety of problems.

(ii) No Gradient Information Required

In GA operators or in their working principles no information about the
gradient of a function is required. In fact, GAs do not require any auxiliary
information except the function values.

(iii) Probabilistic In Nature

One other difference is the operation of GAs is the use of probabilities in their
operators. None of the genetic operators work deterministically. In the reproduction
operator, simulation of the roulette- wheel selection scheme is used to assign the true
number of copies. In the crossover operator, even though good strings (obtained from
the mating pool) are crossed, strings to be crossed are created at random and so is the
case with the crossing sites. In the mutation operator, a random bit is suddenly altered.
The action of these operators may appear to be native, but careful studies may provide
some interesting insights about this type of search.

(iv) Robustness
The basic problem with most of the traditional methods is that they use fixed
transition rules to move one point to another. For instance, in the steepest descent
method, the search direction is always calculated as the negative of the gradient at any
point, because in that direction the education in the function value is maximum. In
trying to solve a multi-modal problem with many local optimum points (interestingly,

Page
18

many real world engineering optimization problems including those of machining

optimization are likely to be multimodal), search procedures may easily get trapped in
one of the local optimum points. in general, traditional methods are not robust. A
robust algorithm can be designed in such a way that it uses the steepest descent
direction most of the time, but also uses the steepest descent direction (or any other
direction) with some probability
GA use search strategies by using probability in all their operators. Since an
initial random population is used, to start with, the search can proceed in any direction
and no major decisions are made in beginning. Later on, when the population begins
to converge in some bit positions, the search directions narrow and a near optimal
solution is achieved. This nature of narrowing the search space as the search progress
is adaptive and is a unique characteristic of genetic algorithms.

1.5

ADVANTAGES

OF

OPTIMIZATION

PROCESS

IN

MACHINING
1) Optimization of process parameters such as feed rate, cutting speed and depth
of cut, should be selected to optimize the economics of machining operations,
as assessed by productivity, total manufacturing cost per component.
2) Optimization will help to increase production rate considerably by reducing
machining time and electrode wear. Optimization is the process of finding a
best, optimal solution for the problem. Machining parameters such as speed,
feed and depth of cut play vital role in machining the given work piece to the
required shape. These have a major affect on the quantity of production, cost
of production and production rate; hence their judicious selection assumes
significance.
3) Optimization of cutting parameters is valuable in terms of providing high
precision and efficient machining. Optimization of machining parameters for
machining is an important step to minimize the machining time and cutting
force, increase productivity and tool life and obtain better surface finish.

Page
19

1.6 GENETIC ALGORITHM

Traditionally, mathematical programming techniques like linear programming,
method of feasible direction, dynamic programming and geometric programming had
been used to solve optimization problems in milling. These traditional methods of
optimization do not fit well over a broad spectrum of problem domains as well as they
may not be robust. Number of constraints and multiple passes make machining
optimization problems complicated. Also these techniques are not ideal for solving
such problems as they give a local optimal solution. Considering the drawbacks of
traditional optimization techniques, the machining problems are optimized by using
evolutionary optimization techniques. Evolutionary computation consists of a variety
of methods including optimization examples that are based on evolution mechanisms
such as biological genetics and natural selection. These methods use the tness
information than that of the functional derivatives making them more robust and
effective. Most commonly used nontraditional optimization technique is genetic
algorithm (GA). However, GA provides a near optimal solution for a complex
problem having large number of variables and constraints as in the case milling
process optimization. Mainly due to difficulty in determination of optimum
controlling parameters such as population size, crossover rate and mutation rate, the
efforts are continuing to use more recent optimization algorithms, which are more
powerful, robust and able to provide accurate solution. [2]
GA is different than traditional optimization techniques in the following four major
ways [4]:
1. GAs work with a coding of the design variables and parameters in the
problem, rather than with the actual parameters themselves.
2. GAs makes use of population-type search. Many different design
points are evaluated during each iteration instead of sequentially
moving from one point to the next.
3. GAs needs only a fitness or objective function value. No derivatives or
gradients are necessary.

Page
20

4. GAs use probabilistic transition rules to find new design points for
exploration rather than using deterministic rules based on gradient
information to find these new points.
To ensure the quality of machining products, and to reduce the machining
costs and increase the machining effectiveness, it is very important to select the
optimal machining parameters. As Compared to traditional optimization methods, a
GA is robust and global. It can be used not only for general optimization problems but
also in indifferent optimization problems and nonconventional optimization problems,
etc. So GAs are widely used for machine learning, function optimizing and system
modeling etc. Although GA is an effective optimization algorithm, it usually takes a
long time to optimize machining parameters because of its slow convergence speed.
The operating domain is defined and changed to be around the optimal point in its
evolutionary processes so that the convergence speed and accuracy are improved.
The mechanics of genetic algorithms is simple, involving copying of binary
strings and the swapping of the binary strings. The simplicity of operation and
computational efficiency are the two main attractions of the genetic algorithm
approach. The computations are carried out in three stages to get a result in one
generation or iteration. The important stages are explained below.
1.6.1 Initialization
During initialization, a solution space of a population size of required quantity
is generated randomly between the limits of the cutting speed, feed rate and depth of
cut
1.6.2 Evaluation
In a GA, the fitness function value is computed for each string in the
population, and the objective is to find a string with the maximum fitness function
value. Since, the objective of this work is to minimize the machining cost function,
the fitness is thus evaluated.
1.6.3 Reproduction

Page
21

The two chromosomes with best fitness and the second best fitness are
allowed to live and produce offspring in the next generation.
1.6.4 Selection
Parents are selected for mating (i.e. crossover) using the Roulette wheel
selection process. The cumulative fitness is used to decide which chromosomes will
be selected to crossover.
The cumulative fitness is calculated in the following steps:
1.

Calculate the total fitness for the population.

2.

Calculate the % fitness for each chromosome.

3. Calculate the cumulative fitness for each chromosome.

1.6.5 Crossover
Crossover is a mechanism for diversification. This operator is mostly
responsible for the progress of the search. It swaps the parent strings partially, causing
offspring to be generated. In this, a crossover site along the length of the string is
selected randomly, and the portions of the strings beyond the crossover site are
swapped.
The crossover used here is one-cut-point method. The crossover exercise is carried
out in the following steps:
(i) Select two random parents based on the cumulative fitness.
(ii) Using the pre-set crossover probability throw a random number.
(iii) Repeat this process until the next generation is full.

Single point
crossover

Page
22

n - point
crossover

Uniform
crossover

Figure.1.3 Crossover[5]

1.6.6 Mutation
Mutation, which is a random modification of a randomly selected string, is
performed after crossover. It is an intensification mechanism. Mutation is done with a
Probability. As each chromosome is added to the next generation, it is examined bit
by bit. Each time a bit is examined.

Figure.1.4 Mutation[5]

1.7 MATHEMATICAL MODEL APPROACH

In this approach, the problem is converted into mathematical models based on
certain criteria. The criteria differ for different problems. In case of automated
machining parameters selection, mathematical model are formulated to determine the

Page
23

machining parameters for a particular objective such as minimization of unit cost or

maximization of production rate. In this approach, empirical equations formulated
based on experimental data for tool life (usually extended tool life equations) and
other practical restrictions on machining variables are used in the model development.
The resultant function from this mathematical modeling is called objective function,
which is subjected to practical constraints. The developed model is then solved using
an optimization technique to yield optimal parameters that reflects the shop floor
capabilities. This procedure is illustrated in Figure 2.1 The success of this approach
depends on the reliability of the empirical equations used in the model formulation.

Figure 1.5 Mathematical modeling

Page
24

CHAPTER TWO

LITERATURE SURVEY
2.1 Process Principle
Electrical discharge machining makes use of high frequency pulse discharge
between the work piece and the electrode to produce the phenomenon of vaporization
and melting at the electric discharge point At the same time, the dielectric is heated
instantly to an extremely high temperature so that the temperature of a small portion
of the work piece material is heated above its melting point and it is then carried
away. In electric discharge machining the tool electrode dose not physically contact
the work piece, and almost non-loaded. The process works very efficiently for the
machining of carbide (Yan et al., 1999).
Electrical discharge machining (EDM) is a manufacturing process by which a
tool cut the required shape in to the work piece within a dielectric fluid. Short
duration discharge is generated in a liquid dielectric gap, which separates tool and
work piece. The material is removed with the erosive effect of the electrical discharge
in the EDM processes a highly complex phenomenon to which scientific knowledge is
incomplete both at macroscopic as well as the microscopic level. In the past 50 years,
research has been done to develop and improve different models of material removal
from both tool and work piece. The main cause for material removal from both of the
electrodes in EDM process is the temperature reached by the surface of both
electrodes. The material of both tool and work piece is removed. Its temperature is
above the melting temperature. This temperature at the surface of both electrodes is
due to the thermal energy which is generated in a discharge channel has a noncylindrical shape however, the assumption that the discharge channel has a cylindrical
shape has been done in order to simplify the model construction. The discharge
channel is composed of a gaseous mix surrounded by the fluid dielectric[6].

Page
25

2.2 Effect of Electrical Parameters

Material removal rate is proportional to current. Material removal rate
increases with pulse duration (Chen et al., 2007). The stochastic thermal nature of the
EDM process makes it difficult to explain experimentally all the effects of electrical
parameters on the individual performance measures. Thus, this section describes
research in the areas of optimisation, monitoring and control of the various electrical
parameters on the performance measures. Pulse parameter, time domain fuzzy logic,
in addition, the emitted radio frequency (RF) or HF signal generated during EDM has
been used to monitor and control the sparking process (Ho and Newman, 2003).
Electrical discharge machine has many electrical parameters, are important in
responses like MRR, SR and EWR. EDM processes is a highly complex phenomenon
to which scientific knowledge is incomplete both at macroscopic as well as the
microscopic level. Along with electrical parameters non electrical parameters like
electrode rotation and electrode shape is important factor in MRR and geometrical
accuracy.

2.3 Effect of Non-Electrical Parameters

2.3.1 Effect of flushing conditions
Insufficient flushing result in the stagnation of the dielectric, build up of
machining residue in the gap short circuits, arcs and low material removal rate
(MRR), and culminates in the stalling of the machining process.
Rotary electrical discharge machining in induced magnetic field produced
higher material removal rate and decrease electrode were rate higher geometric
trueness, resulting in better dimensional control on the work piece. Positive polarity
gives higher MRR & lower EWR[7].
Innovative kinematic schemes and experimental proof of concept for the
seemingly impossible task of using rotating tools for sinking polygonal shapes with
sharp corners are presented. The curvilinear tools and the tool paths proposed are
motivated by the principle of a Reuleaux Triangle. Application of this technology
enhances flushing of the working gap through rotation and translation of the tool,
Page
26

while concurrently maximizing the frontal machining area is shown in figure 2.1. The
geometry of RT tools further presents the prospect of augmenting process
performance by external jet flushing, which can render the removal rate to be
independent of the machining depth, unlike conventional EDM (Ziada and Koshy,
2007).

Figure 2.1 Generation of a square with a sharp corner using a modified RT [].
In micro EDM, the discharge gap is very small, and the size of the electro8de
is too small to use internal and/or external flushing to remove debris. In this paper, a
new approach using planetary movement of the electrode is proposed to reduce the
debris concentration and improve precision. The planetary movement of electrode
provides extra space for debris removal. Therefore, the material removal rate
increases and the electrode wear reduce.

2.3.2 Effect of electrode rotation

Increasing the rotational speed of the tool electrode can improve the debris
discharge and reduce the expansion of the micro-hole, but it has no great effect on the
tool electrode wear rate.
MRR increases with an increase of rotational speed of the tool enhances the
flow velocity of the work fluid flushing into the discharge gap, the migration velocity
of discharge point on the tool surface increases. The cooling effect of the tool and the
ejecting effect of the eroded materials enhance, the electrical discharges become

Page
27

strong and stable: therefore, the MRR increases with an increase of rotational speed of
the tool (Liu et al., 2009).

Figure 2.2 The material removal depth vs. the rpm of the RDE electrode with the
discharge current as a parameter[8]

Figure 2.3 Rotations or rotary EDM[9]

Rotating disk and conventional electrode:

Effect of parameter on fixed tooling and rotary EDM during machining of
OHNS die still the following conclusions are drawn. Peak current (I p ) is most
significant parameter for MRR (mm3/min) with 76.52% and 87.11% contribution for
fixed and rotary EDM respectively (Manna et al., 2005).

Page
28

Stationary electrode for the pick current 14 ampere, pulse on time 150 micro
second, duty cycle 8, gap voltage 40 volt response MRR is14.77 mm3//min. Rotary
electrode at 150 rpm, pick current 14 ampere, pulse on time 100 micro second, duty
cycle 12, gap voltage 40 volt response MRR is 23.14 mm3//min (Manna et al., 2005).

Figure 2.4 Vibratory, rotary, vibratory & rotary[10]

Effect of ultrasonic vibration and vibro-rotary increases MRR, TWR and R a

value. Semi finishing MRR increase by 35% and 100% by vibro rotary (Ghoreishi and
Atkinson, 2002).

Figure 2.5 Comparison between the traditional EDM and the electrode orbiting EDM:
(a) die-sinking machining without orbiting; (b) dimensional deviation of the cavity
arising from the orbital motion[10]

Page
29

2.3.3 Effect of ultrasonic vibration

Figure 2.6 Effect of vibration[10]

The machining times for machining types A, B and D are lower than for the
machining type C since mandrel rotation and vibration effectively remove debris and
inhibit adhesion from the tool electrode.
The effect of tool electrode wear to the total energy of discharge pulses has
also been known, since the discharge pulse energy is not only used to machine the
work piece, but also used to machine the tool electrode. This characteristic is very
important for precision micro-3-D surface machining EDM s that utilizes simpleshaped electrodes (Soni, 1994). Ultrasonic vibration with pulse in EDM Process is
strongly influenced by the hydrostatic pressure which governs the hydrodynamic
pressure change during the discharge (Kremer et al., 1991). The influence of
ultrasonic is not significant on open circuit pluses but the short circuit and arching
pulses are significantly reduced. Ultrasonic do not seem to have any significant effect
on energy per active pluses[11].
Surface roughness: The main effect of ultrasonic vibrations is seen for high
values of amplitude only: for 8 m amplitude, the results show a small increase in R a
and R max , due to the fact that more melted metal being ejected by every discharge,
craters are deeper. The total affected layer is thinner with ultrasonic vibration.
Residual stresses are same value with or without USEDM (Kremer et al., 1991).

Page
30

Figure 2.7 Feed rate mechanism in the EDM processes. (a) Without machining, feed
speed 50 mm/s, (b) first second, 5 mm/s feed rate 50 mm/s and (c) during machining,
feed rate 5 mm/s (Mahardika et al. 2008).

Al should be the easiest material to machine; however, its machining time was
the highest. In order to evaluate this phenomenon, discharge pulse count monitoring
was performed. The result shows that Al is actually the easiest material to machine
compared to the other materials; in the first second of machining, 21% of material
was removed Compared to only 3% for W. Thus, discharge pulse count monitoring is
very effective to explain the EDM processes in relation to machining complications
(Mahardika and Mitsui, 2008)

2.3.4 Effect of Dielectric Fluid

The metal removal rate, electrode wear, surface finish, dimensional accuracy,
surface hardness and cracking depend on the size and morphology of the craters
formed. The surface texture also depends on the size, shape and depth of the craters
which in turn depend on the applied current, voltage and pulse duration. In addition,
the physico- mechanical properties of the work and electrode materials, such as
thermal conductivity, electrical resistively, specific heat, melting temperature and
hardness, also has a considerable influence on the machining process. The material
removal in EDM is by melting and vaporization of material and the top surface
resolidifies and cools at a high rate. This results in change in the original hardness and
chemical composition of the work piece and tool. Choice of dielectric fluid also plays
an important role. The debris is produced by EDM, which consists essentially of
maintaining a repetitive spark discharge between tool and work piece electrodes.

Page
31

These electrodes are separated with an intentional gap known as the spark gap and
submerged in a dielectric fluid. The spark discharge causes small regions of the
electrodes to be heated rapidly above the melting temperature or vaporized regions to
produce small molten droplets (powder particles) which are ejected into the dielectric
to be rapidly quenched. The debris is an alloy of materials formed from the work and
tool electrodes and the dielectric. The change in chemical imposition occurs due to
migration of material from either of the electrodes and dielectric[11].

2.4 Rotary Attachment

New developments are emerging in electro-discharge machining. The rotary
attachment can be obtained by:

2.4.1 Rotating a workpiece

One case for rotary EDM is by rotation of work piece. This is a special case of
EDM where parts with simple geometry can be easily made. Thus intricate shapes
cannot be made easily.

2.4.2 Rotating the electrode

The rotary motion to the electrode improves the performance measures of the
EDM process. It serves as an effective gap flushing technique, which significantly
improves the MRR and surface roughness. An improvement in MRR due to the better
flushing action and sparking efficiency with little tool wear but the SR was high.
2.4.3 Different rotary attachments to EDM
Rotary attachment with special purpose motor: In this attachment special
purpose motor is used. It consists of motor with inner cavity for passing the electrode.
There are problem of perfect insulation of magnetic field of motor, also cost is more
(Ghoreishi and Atkinson, 2002).

Page
32

Figure 2.8 Rotary attachment with special purpose motor (Ghoreishi and Atkinson,
2002).

Figure 2.9 Rotary attachments with outer brushes[12]

This may be one of the rotary attachments used for rotating electrode. In this the
carbon brushes are used to transmit current to rotating electrode. However, this
attachment has following disadvantages.

Page
33

i) The fabrication cost is high due to special manufacturing.

ii) The maintenance cost is more.
iii) Losses are more

Figure 2.10 Sketch of equipment (Shih and Shu, 2007).

Figure 2.11 Discharge mechanisms: experiment equipment (Chen et al., 2007).

Comparing the all above rotary equipments and attachments, the rotary
attachment using timing belt is more beneficial to study the effect of shape and
rotation of electrode and therefore it is required to be developed[12].
Page
34

2.5 Performance Measurement

2.5.1 Material removal rate

It was observed that the volume of material removed increased with the
increase in supply voltage, and this could be due to the generation of a large number
of positively charged hydrogen bubbles at the higher value of supply voltage. These
hydrogen bubbles act as insulating medium, which become enlarged with time and
envelope the tool. Due to ohmic heating, these bubbles are burst, providing a way for
discharge near the tool electrolyte interface and, hence, contributing to the improved
machining. The magnitude of the discharge energy remains proportional to the supply
voltage under the specific conductance of electrolyte (Chak and Rao, 2007).

The MRR improves with the rotating electrode due to improved flushing
action and sparking efficiency. However, surface roughness is higher. The MRR is
better in through-hole machining than in blind-hole machining at all rotating speeds
(Soni and Chakraverti, 1994). Rotary disk electrode improves the productivity of
EDM. MRR is superior to stationary electrode (Koshy et al., 1993).

2.5.2 Tool wear rate

There are two possibilities for the electrode to gain weight: (1) the dielectric
fluid generally is made of hydrocarbon compounds. In a machining process, the
electric arc will release great heat and cause hydrocarbon compounds to decompose
into carbons and other compounds. The melting point of carbon is up to 3500C.
When carbons adhere to an electrodes surface, they protect the electrode from wear
and this greatly reduces electrodes wear rate. (2)When cutting debris vaporized from
a work piece splashes onto electrodes and mixes with electrodes material, an alloy
clot with a different colour is formed on electrodes surface.

Based on this theory, another special machining process may emerge if

parameters setting can be controlled appropriately to allow the electrodes material
uniformly sprays onto a work piece (Shih and shu, 2007).

Page
35

The tool wear rate increases with increasing speed, but the wear ratio is not
significantly affected. Electrode corner wear and hole corner radius in blind-hole
machining are lower with the rotating electrode (Soni and Chakraverti, 1994).
W i -W f
TWR =

(density of electrode *t)*1000

W i =initial weight of electrode in g, W f = final weight of electrode in g, t = period of

trial in min (Mohana et al., 2004).

2.5.3 Surface roughness

Surface Finish is a function of three parameters that is peak discharge current,
discharge voltage and pulse on time all of which power supply settings. Methods of
improving surface quality:
Surface alloying: Ball burnishing machining: Powder addictives: Surface finish
simulation:

Figure 2.12 A newly developed electrode tool of B-EDM (Yan et al., 2000).

Page
36

Figure 2.13 Schematic experimental surface profile of Al 2 O 3 /6061 composite for the
B-EDM process. (Section A is a surface that has been subject to EDM; section B is a
surface that has been subjected to B-EDM (Yan et al., 2000).

2.6 GA optimization

Dereli, T. and Filiz, H. I. explained the application of GA for determination of

optimal sequence of machining operations based on either minimum tool change or
minimum tool traveling distance or safety. Combination of these criteria also might be
used. They have also explained how the optimum position of tools on the automatic
tool changer or turret magazine of a CNC machine tool is obtained by using GA.
P.

Palanisamy,

I.

Rajendran,

S.

Shanmugasundaram described

the

optimization of cutting parameters is valuable in terms of providing high precision

and efficient machining. Optimization of machining parameters for milling is an
important step to minimize the machining time and cutting force, increase
productivity and tool life and obtain better surface finish. In this work a mathematical
model has been developed based on both the material behavior and the machine
dynamics to determine cutting force for milling operations. The system used for
optimization is based on powerful artificial intelligence called genetic algorithms
(GA). The machining time is considered as the objective function and constraints are
tool life, limits of feed rate, depth of cut, cutting speed, surface roughness, cutting

Page
37

force and amplitude of vibrations while maintaining a constant material removal

rate[13].

Zain et al, applied GA to optimize cutting conditions for minimizing surface

roughness in end milling machining process. They observed the optimal effect of the
radial rake angle of the tool, combined with speed and feed rate cutting conditions in
influencing the surface roughness result. The analysis of their study has proven that
the GA technique is capable of estimating the optimal cutting conditions that yield
the minimum surface roughness value. With the highest speed, lowest feed rate and
highest radial rake angle of the cutting conditions scale, the GA technique
recommends 0.138 m as the best minimum predicted surface roughness value. This
means the GA technique has decreased the minimum surface roughness value of the
experimental sample data, regression modeling, and response surface methodology
technique by about 27%, 26% and 50% respectively. [8]
Sardinas et al, presents a multi-objective optimization technique, based on
genetic algorithms, to optimize the cutting parameters in turning processes: cutting
depth, feed and speed. Two conflicting objectives, tool life and operation time, are
simultaneously optimized. The proposed model uses a microgenetic algorithm in
order to obtain the non-dominated points and build the Pareto front graph. An
application sample is developed and its results are analyzed for several different
production conditions. They concluded that multi-objective optimization offers
greatest amount of information in order to make a decision on selecting cutting
parameters in turning. By means of Pareto frontier graphics, several different
situations may be considered, facilitating the choice of right parameters for any
condition. [17]

Page
38

OBJECTIVES OF THIS PROJECT WORK ARE

1. To explore the effect of process parameters on the MRR, EWR and SR using
statistical analysis.
2. To determine the co-relationship between the input parameters (rotational speed,
duty factor and pulse current) and the response variable (MRR, EWR and SR) using a
regression model.
3. To validate the developed model.

Page
39

CHAPTER THREE

EXPERIMENTAL WORK
3.1 Planning of Experiments
3.1.1 Design of Experiments
To use the statistical approach in designing and analyzing an experiment, it is
necessary to have a clear idea in advance of exactly what is to be studied, how the
data are to be collected, and at least a qualitative understanding of how these data
are to be analysed[12].The present experiments were designed on the basis of these
guidelines.

The step-by-step procedure which was used in designing these

experiments is outlined below:

1. Create problem statement

The objective of the experiments is to determine the influence of various process

parameters and their interactions on the response in rotary EDM by developing
mathematical models.
2. Selection of response variables

In selecting the response variables, it should be ensured that these variables

provide useful information about the process performance under study. Following
measures of performance (response variables) were chosen:

Metal removal rate (MRR)

Electrode wear rate(EWR)

Surface Roughness (SR)

3. Choice of experimental design and process variables:

Results of trial experiments are interpreted and following process variables are
selected for further experimentation with circular shape electrode.

Page
40

Experiments are carried out with copper electrode of 12 mm diameter on SKD11.

Work material of 6 mm thickness and electrode depth is taken 12mm for machining
by varying Electrode Rotation,% Duty Factor and Pulse Current with two level for
Circular.Full Factorial 32 eight experiments and replication that is 16 experiments are
carried for each shape.

Table 3.1 Control factors and their levels for experiment

S. N.

Control Factors

Low level (-1) High level (+1)

1
2
3

A: Current (ampere), I p 6
B: Duty factor (%),t
3
C: Electrode rotation 80

24
12
155

Considering machine specifications and past literature other machine parameters are
kept constant or they were set at their optimum levels. Such parameters and their
values, which remain constant throughout the experiment, are given below.

3.1.2 Workpiece material

Material Removing is directly related to electrical parameters like Pulse
Current, Duty Cycle. Debris Removal is enhanced with electrode rotation thus
improving MRR and geometrical accuracy in through hole of 12mm diameter on
6mm thick plate of SKD11, which is clean, high quality, homogeneous, uniform
hardness alloy used for cold working tools and dies. Electrolytic Copper as electrode
(99.536 %) and Commercial grade kerosene is used as dielectric fluid.

Page
41

Table 3.2 Properties of SKD11 (unit:

wt.%)[11]
C

Si

Mn

Cr

Mo

Ni

1.59 0.13 0.18 0.020 0.01 11.5 0.81 0.27 0.28

Cu
0.045

Chemical compositions are adjusted to meet a specific size of tool block, and the
hardness is controlled uniformly throughout the tool block, regardless of its size. Even
after re-sinking, the block can be used under the same conditions as before, and
extended service life is assured. Excellent wear resistance, high strength features:

3.2 Experimentation
3.2.1

Equipments
The electric discharge machine (Make-Electronica, model-electraplus leader 1

znc) with constant servo gap head facility was used for conducting the experiments.
EDM is used with developed low cost rotary attachment. The machining parameters
are controlled using panel box. These parameter include variable like peak current
,duty factor and electrode rotation on attachment control panel .DC motor combined
with reduction gear box giving speed range of 40 -180 rpm is fitted to the plate with
insulator. Speed is varied with control separately attached.

Plate is directly attached to quill .Drill chuck is used to hold electrode and belt
drive is used for transmit ion.

Page
42

Table 3.3 Technical specifications of EDM

Work Table Dimension

550350mm

Traverses(x, y, z)

300, 200, 250 mm

Max .Job height above the Table

250

Pulse generator

550znc

Pulse generator type

MOSFET

Max.MRR Cu-st

350 mm3 /min

Figure 3.1 electrical discharge machines (Make-Electronica, Leader)

Page
43

Figure 3.2 Developed low cost rotary attachment

Figure 3.3 Trimos Vertical

Figure 3.4 Precision weighing balances

Page
44

3.2.2 Rotary attachment

The rotary attachment using belt drive is more beneficial and is required to be
developed.

Figure 3.5 Tentative schematic of rotary attachment[10].

In this attachment the rotation of electrode is achieved by d.c. motor through

timing belt. The stepper motor and rotating electrode are mounted on a conducting
plate. Rotating electrode is housed in the needle bearing. The current is passed to
rotating electrode by stationary electrode through needle bearing. This attachment will
be used as actual attachment for further experimentation, as it is easy to manufacture.
Benefits of rotary attachment:
i) The mechanism is simple.
ii) System is automated.
iii) Overall cost of assembly is low.
iv) Weight of attachment is low.

Page
45

EDM attachment consists of following parts:

1.

Electrically conducting plate

2.

Insulating plate

3.

Permanent magnet D. C. motor

4.

Speed reduction box

5.

Belt drive system

6.

Collet

Specifications of parts

1.

Electrically conducting plate:

Figure 3.6 electrically conducting plate

The base plate is made up of steel. The dimensions of plate are 300 x 150 x 10 mm.
The plate is in direct contact with quill head which transmits current to electrode
through plate. The plate dimensions are selected from quill head dimensions which
are 150 x 150 mm.
Insulating plate: The insulating plate is made up of Bakelite which is electrically nonconducting material. The dimensions of plate are 165 x 110 x 8.5 mm. The plate is
placed in between the motor and conducting plate, to protect motor from electrical
damage. Total weight of attachment is 6.668 kg.

Figure 3.7 insulating plate

Page
46

2.

Permanent magnet D. C. motor:

The motor specifications are as follows:

Model: PM040
KW: 0.4Rpm: 2000
Volts: 24A
3.

Speed reduction box:

The speed range for experiments is 60 to 200 rpm. Thus the 10 % speed reduction box
is attached to motor shaft.
4.

Belt drive system:

Figure 3.8 Belt and pulley

The belt drive system consists of two pulleys and a toothed rubber belt. Pulleys are
made up of plastic material to reduce the weight of attachment. The diameter of
pulley is 50 mm. Both pulleys are made toothed to avoid slipping. The power is
transmitted from driving to driven pulley. The dimensions of belt are: Length of belt:
480 mm Thickness of belt: 4 mm
Width of belt: 25 mm.

5.

Collet: The collet is attached on driven shaft and is used to clamp the

electrode.
Page
47

Figure 3.9 Developed low cost Rotary Attachment.

3.2.3 Experimental design matrix

The selection of which design to choose is determined on the basis of the
objectives of the experiment, the costs involved (work piece material, tools, time) and
the choice of factors and levels. The design must be able to maximize the amount
of information to be obtained from the experiment and minimize the number of
trials, in order to keep the costs low.

FFDs with replications offer a complete

picture on the relationship between the dependent and the independent variables but
they often result in a large number of trials, are costly and time- consuming.
Alternatively, FrFD experiments result in a lower number of trials, but provide
only a general assessment of the relationship between the main factors and may
ignore some of their interactions[12].
It was proposed to determine the effect of all possible interactions in the
present experiment. A full factorial design (FFD) only can help in estimating such
interactions. Hence, 23 FFD (three factors, each at two levels) was chosen for this
study. A complete replicate of this design requires 24 = 16 experimental runs for the
circular shape electrode.

Page
48

Table 3.4 Experimental design matrices

Run
Order
1

Rotation

Duty

Electrode
Factor
Table no.3.6
80
3

Pulse
Current
6

155

80

12

155

12

80

24

155

24

80

12

24

155

12

24

3.2.4 Machining set-up

First step of experiment selects full factorial design for experimentation. Pulse
current, duty factor and electrode rotation with two levels. Eight experiments for a
electrode. To achieve accuracy, two replication is made and experiments are
randomly performed. Flushing pressure 0.7kg/cm2, pulse on time 100 s, electrode lift
4 mm, polarity

positive, gap voltage -85 volts, anti arc sensitivity 6,retraction

distance-4 mm, work time 1.2.

Level of factors is decided by performing screening experiments for electrode.

Four levels are chosen and varying one factor and keeping other three constant. Three
shape and two level given better MRR, EWR, SR performance.

Page
49

Work piece of SKD11, 6 mm thick plate is machined for 12 mm depth of electrode

for getting through hole. Surface roughness is measured with Mitutoya make surface
tester. MRR, EWR, SR performance is checked for optimization.

3.2.5 Measurement of responses

1.

Metal removal rate (MRR)

The MRR for each specimen work piece was calculated by weight difference of the
specimen before and after machining. The weight measurements were done on
Contech precision weighing balance (l.c.0.001mm, maximum capacity 1000 g).
Besides, as the machining progressed, machining time was recorded after through
hole of 6 mm on thick plate of SKD11 steel with 12 mm diameter electrode This was
done with a view to determine the variation of MRR(mm3/min) during
experimentation.

2. Electrode wear rate (EWR)

The EWR for each copper electrode was calculated by weight difference of electrode
before and after machining of through hole of 6 mm thick plate. Precision balance is
used for weighing.

3.

Surface Finish (SR)

After machining, the specimens were cleaned and dried .Their surface roughness is
measured with Surface roughness tester SJ 301, stylus type .Specifications of SJ 301
Tester are Parameter- Ra R q R z , Filter- 2R- C type, Cut of length 0.08, 0.25, 0.8, 2.5
mm, Resolution- 0.01 m, Tip radius- 5 m, 2 m, Stylus material- diamond, Radius
of skid curvature- 40 mm. The cut-off length for each measurement was 0.8 mm. One
such cut-off lengths were measured on each specimen and the average surface values
were taken.

Page
50

After machining, the specimens were cleaned and dried and their surface roughness
was assessed using the stylus method. All the measurements were carried out with a
Taylor Hobson SURTRONIC 3+ instrument.
Several investigators have questioned the reliability of stylus method for
surface roughness measurement on EDMed surfaces. To examine this, EDMed
fourteen specimens of die steel under identical conditions. Their surface values, R a
(arithmetic mean roughness value), R q (root mean square value), R t (maximum peak
to valley height) and R tm (mean peak to valley height) were measured. The means and
standard deviations of these values were evaluated to check on the consistency in each
of these measurements. The results showed that among the four surface roughness
parameters investigated, R a gave the least coefficient of variation of 13.2%. In view
of this and the fact that the stylus method is the most practical means of assessing
surface finish on the shopfloor, Ra values were used to represent the surface quality of
the EDMed specimens in the present study.

Table 3.5 Constant values

Sr.no

Input Parameter

Values

Polarity

Work time

1.2

sec

Flushing Pressure

0.7

Kg/cm3

Pulse on Time (Ton)

100

Retraction Distance

mm

Asen and sen

Gap voltage

85

Page
51

Unit

CHAPTER 4

RESULTS AND DISCUSSION

The experimental observations for the rotary EDM with circular shape of electrode is
given in Tables 4.1. The statistical analysis of experimental data was then carried out
using Minitab 15 Software. The effect of peak current, % duty cycle, electrode
rotation for three different shapes on material removal, electrode wear, surface
roughness is discussed separately as follows. The analysis of each response along
with its interpretations is presented in the subsections to follow.
Table 4.1 Experimental results
Std.

electrode
rotation

order

duty

pulse
current
ampere

factor

rpm

MRR

EWR

SR

mm3/
min

mm3/
min

Ra
m

80

4.39

0.035

2.66

155

4.78

0.037

3.51

80

12

8.18

0.025

3.32

155

12

7.60

0.048

3.32

80

24

11.29

3.077

4.86

155

24

17.13

3.618

6.61

80

12

24

36.10

5.307

4.49

155

12

24

38.34

6.292

3.54

Page
52

4.1 Regression equations

Effect of each factor and interaction on MRR of SKD11 steel with electrode
was first estimated with a view to have preliminary information regarding which
factors and interactions are significant. Minitab 15 software(ANOVA) by choosing
full factorial with two replication in general linear model gives us Pareto charts which
are plotted in decreasing order of importance of each factor and their interactions as
shown in figure 4.1, 4.2 and 4.3. These charts help in testing the statistical
significance of the above effects. This aspect is discussed in detail later in this section.

In the next step, full models for MRR incorporating all the main effects and
interactions (2-factor and above) were obtained. The analysis of variance, which helps
in formally testing the significance of all the above main effects and interactions, was
then carried out. Tables 4.4 present the correspondin results.

Graphical displays such as Pareto charts and main effect plots, as shown in
Figures 4.1 to 4.3, were also used to determine the significance of the factors and
interactions. The Pareto charts show each of the estimated effects in decreasing order
of magnitude. The length of each bar is proportional to the standardised effect divided
by its standard error. This is equivalent to computing a t-statistic for each effect. The
vertical line in this chart can be used to judge which effects are statistically
significant. Any bars which extend beyond the line in this chart correspond to the
effects which are statistically significant at the 95% confidence level.

The above analysis shows that general linear model of first-order regression
obtained on the basis of full factorial (23) experiments are adequate for predicting the
MRR with varying parameter. The proposed models correspond to a wide range of
experimental conditions namely in rotary edm varying shape of electrode for increase
in MRR.

Page
53

Final regression equation for MRR in terms of actual factors:

MRR = - 28 + 0.0519r + 2.20t + 1.45i

.... (1)

Figure 4.1 Main effect plot and pareto diagram of MRR

Duty Factor(%)

Electrode Rotation (rpm)

25
20
15
10

Mean

5
80

155

12

Pulse Current(Ip)
25
20
15
10
5
6

24

(response is MRR, Alpha = 0.05)

2.31
C
B

Term

BC
A
AC
AB

F actor
A
B
C

ABC
0

N ame
E lectrode Rotation (rpm)
D uty F actor(% )
P ulse C urrent(Ip)

10
15
20
Standardized Effect

Page
54

25

Final regression equation for EWR in terms of actual factor:

EWR= - 0.694 + 0.00604r 0.0295t + 0.0626i

.(2)

Figure 4.2 Main effect plot and pareto diagram of EWR

Electrode Rotation (rpm)

Duty Factor(%)

Mean

1
0
80

155

Pulse Current(Ip)

Main Effect Plot

2
1
0
6

24

(response is EWR, Alpha = 0.05)

2.306
C
B

Term

BC
A
AC
AB

F actor
A
B
C

ABC
0.0

0.5

N ame
E lectrode Rotation (rpm)
Duty F actor(% )
P ulse C urrent(Ip)

1.0
1.5
2.0
2.5
Standardized Effect

3.0

Page
55

3.5

12

Final regression equation for SR in terms of actual factors:

SR =2.52 + 0.00763r 0.104t + 0.100i

..(3)

Figure 4.3 Main Effect Plot and Pareto diagram on SR

Main Effect Plot
Electrode Rotation (rpm)

Duty Factor(%)

5.0
4.5
4.0

Mean

3.5
3.0

80

155

Pulse Current(Ip)
5.0
4.5
4.0
3.5
3.0

24

(response is SR, Alpha = 0.05)

2.306
C
B

Term

BC
ABC
A
AC

F actor
A
B
C

AB
0

N ame
E lectrode Rotation (rpm)
D uty F actor(% )
P ulse C urrent(Ip)

2
3
Standardized Effect

Page
56

12

4.2 GA optimization
The genetic algorithm is a method for solving both constrained and
unconstrained optimization problems and is based on natural selection, the process
that drives biological evolution. Fig. 6 shows the flow of GA technique in order to
optimize the problem. The solution of an optimization problem starts with a set
optimal solution that is known as chromosomes. The entire set of these chromosomes
include populations which are randomly selected. The chromosomes evolve during
several iterations or generations. New generations known as offsprings are generated
by using the crossover and mutation techniques. Crossover involves the process of
splitting two chromosomes and then combining one-half of each chromosome with
the other pair. Mutation involves the process of flipping a chromosome. The genetic
algorithm repeatedly modifies a population of individual solutions. At each step, the
GA selects individuals at random from the current population to be parents and uses
them to produces the children for the next generation. Over successive generations,
the population evolves toward an optimal solution.
As shown in Fig. 4.4 in order to get an optimal solution, the generated
population is evaluated by employing a certain fitness criterion. Some conditions for
obtaining the best fitness function are:
1. The algorithm stops when the number of generations reaches the value of
generations.
2. The algorithm stops after running for an amount of time in seconds equal to the
time limit.
3. The algorithm stops when the value of fitness function for the best point in the
current population is less than or equal to the fitness limit.
4. The algorithm stops when the weighted average changes in the fitness function
value over stall generations and is less than function tolerance.
5. The algorithm stops if there is no improvement in the objective function during an
interval of time in seconds equal to the stall time limit.

Page
57

6. The algorithm runs until the weighted average changes in the fitness function value
over stall generations and is less than function tolerance.
7. The non-linear constraint tolerance is not used as a stopping criterion. It is used to
determine the feasibility with respect to the non-linear constraints.
Primarily, the evaluation process is repeated until one chromosome with the best
fitness is taken as the optimum solution for the problem.

Fig.4.4 Flowchart of GA for optimization

4.3 Optimization model

MRR, EWR and SR models obtained from regression analysis is used as objective
function (i.e. optimization model).

Page
58

4.3.1 Decision variables

Three input parameters, i.e., electrode rotation(r), duty factor (t), pulse current (i).

4.3.2 Objective functions:

Maxinmize MRR:
MRR

= - 28 + 0.0519r + 2.20t + 1.45i,

Minimize EWR:
EWR= - 0.694 + 0.00604r 0.0295t + 0.0626i
Minimize SR:
SR =2.52 + 0.00763r 0.104t + 0.100i
4.3.3 Variable bounds
Following variable bounds were formulated based on the survey of range of values of
decision variables are presented as below
Rotation = 80 r 155 rpm
Duty factor = 3 t 12 %
Pulse current = 6 i 24 amp

4.4 GA implementation
Binary coded genetic algorithm with an elitist strategy for replacement is used in this
technique. It operates on the principle of the survival of the fittest. With MINLP
problems, GA generally suffers from the prematurity problem and may require many
runs to avoid the trap of local minima. However, the problem being investigated is a
special case of the general MINLP problem as the constraints are independent of the
integer variable (position in the lookup table). With a suitable fine tuning of the
parameters for the genetic operators it is possible to obtain the global optimum results
using the proposed technique.

Page
59

Objective function:Function [EWR SR MMR] = RA_final(x)

EWR = -0.694 + 0.00601*x(1) - 0.0295*x(2) + 0.0626*x(3); % min
SR = 2.52 - 0.00763*x(1) - 0.104*x(2) + 0.100*x(3); % min
MMR = -28.0 + 0.0519*x(1) + 2.20*x(2) + 1.45*x(3); % max
End
Constraint coding:clear; clc;
% arg[dim iter nop per]
% div[orig cross mut]
% val[lower1 upper1; lower2 upper2]
% cost - handle to cost function
arg = [3 20 40 20];
val = [80 155; 3 12; 6 24]; % r t i
div = [20 40 40];
result = GA(arg, val, div, @RA)
[EWR SR MMR] = RA_final(result)

GA coding:function result = GA(arg, val,div, cost)

% arg[dim iter nop per]
% div[orig cross mut]
% val[lower1 upper1; lower2 upper2]
% cost - handle to cost function
dim = arg(1);
iter = arg(2);
nop = arg(3);
per = arg(4)/100;

% dimensions : No. of variables to be solved for

% iterations
% No. of Particles
% percentage of original population

orig = div(1)/100;
cross = div(2)/100;
mut = div(3)/100;
gen1 = zeros(dim, nop); % create place holder for population -- dim :rows and nop :
columns
for i = 1:dim
% run this sequence for i dimensions..
gen1(i,:) = val(i,1) + (val(i,2)-val(i,1))*rand(1,nop); % Generate nop particles for
1st generation within lower and upper limit

Page
60

end

for i = 1:iter
% for each iteration
i
res = zeros(dim+1, nop); % create place holder for 1) cost 2) population -- dim +
1(cost) :rows and nop : columns
for j = 1:nop
% for each particle
res(1,j) = cost(gen1(:,j)); % calculate and store cost each set of particles..
for k = 1:dim
res(1+k,j) = gen1(k,j); % store corresponding particle .. for linked sorting..
end
end
res = sortrows(res');
% sort according to first column...
gen1_o = res(1:size(res,1)*orig,2:dim+1)'; % Generation created by retaining
original values...
res(ceil(nop*per)+1:nop,:) = []; % Eliminate values other than required/defined
by per..
res(1,:);
gen1_c = crossover(res, cross*nop,val); % Create cross percent population by
crossover
gen1_m = mutate(res, mut*nop,val);
gen1 = [gen1_o gen1_c gen1_m];
% combine new population from (orig
,cross, etc..)
end
result = res(1,2:dim+1);
% The best particle at the end of program..
end

Mutation coding:% inputs

% - res : result + population, matrix
% - mut: no. of particles required from this function
% output
% - gen_m : the actual particles returned
function gen_m = mutate(res, mut, val)
gen_m = -1*ones(size(res,2)-1, mut); % create place holder for mutation
for i = 1 : mut
% for each particles that is to be returned
sel = ceil(rand(1,1)*size(res,1)); % take random one integer from the population
matrix
for j = 2 : size(res,2)
% j starts from 2 since - 1st column is cost, 2nd
onward the actual variable start
while gen_m(j-1,i)>val(j-1,2) || gen_m(j-1,i)<val(j-1,1)
d1 = round(res(sel,j)*100); % decimal value of first parent * 1000
b1 = dec2bin(d1,14);
% binary value of 14 bits of first parent
Page
61

bit_flip = ceil(rand(1,1)*14); % select random bit flip position

if b1(bit_flip) == '0'
b1(bit_flip) = '1';
else
b1(bit_flip) = '0';
end

% toggle bit

gen_m(j-1,i) = bin2dec(b1)/100; % decimal value of string created is stored in

gen_m
end
end
end
end
Crossover coding:% inputs
% - res : result + population, matrix
% - cross: no. of particles required from this function
% output
% - gen_c : the actual particles returned
function gen_c = crossover(res, cross, val)
gen_c = -1*ones(size(res,2)-1, cross);
for i = 1 : cross
% for each particles that is to be returned
for j = 2 : size(res,2)
% j starts from 2 since - 1st column is cost, 2nd
onward the actual variable start
while gen_c(j-1,i)>val(j-1,2) || gen_c(j-1,i)<val(j-1,1)
sel = ceil(rand(1,2)*size(res,1)); % take random two integers from the
population matrix
d1 = round(res(sel(1),j)*100); % decimal value of first parent * 1000
d2 = round(res(sel(2),j)*100); % decimal value of second parent * 1000
b1 = dec2bin(d1,14);
% binary value of 14 bits of first parent
b2 = dec2bin(d2,14);
% binary value of 14 bits of second parent
temp = strcat(b1(1:7), b2(8:14)); % string containing 1st 7 bits from b1 and
last 7 bits from b2
gen_c(j-1,i) = bin2dec(temp)/100; % decimal value of string created is stored
in gen_c
end
end
end
end

4.5. Output from genetic algorithm

Page
62

After running the GA program 10 times in Matlab software following 10 optimized

conditions of input variables are obtained for minimizing the cutting force.
Table4.2 Optimal set of process parameters with its respective MRR, EWR
and SR
R

MRR

EWR

SR

153.56

11.99

6.66

16.0048

0.2921

0.7674

154.99

11.91

6.46

15.789

0.2882

0.7364

143.34

11.99

6.03

14.5608

0.1912

0.7824

154.86

11.03

6.5

15.4882

0.2946

0.7581

153.34

12

10.48

21.5962

0.5396

1.166

154.57

11.99

10.48

23.1281

0.5373

1.1417

152.93

12

11.58

21.4267

0.595

1.26

153.54

11.99

10.4

21.4549

0.5261

1.1415

Table 4.3 Optimal Set of process parameters for minimization of MRR, EWR and SR
(predicted results)
r
153.54

t
11.99

i
10.4

MRR
21.4549

EWR
0.5261

SR
1.1415

4.6 Confirmation and Validation of Optimal Settings of Process Parameters

The objective is to determine the values of control parameters (r, t, i) in such a way
that the process output responses i.e.MRR, EWR and SR converge towards their
target values. This is done through minimization of the error function. Table 4.4
represents the average obtained values of process response selected for conducting
confirmation test by experiments.

Page
63

Table 4.4 Optimal Set of process parameters for minimization of SR and EWR, and
maximization of MRR (experimental results)
r

MRR

EWR

Sr

153.54

11.99

10.4

22.104

0.5491

1.15

A comparison between predicted and desired values of process responses are

observed from Table 4.3 and 4.4 for the optimal setting for process parameters. The
error between predicted and the target (experimental) values of process responses is
calculated as follows (Kolahan and Bironro, 2008)
Error (%) = 100 X

(Target Predicted )
Predicted

Table 4.5 Comparison between Target and Predicted Optimal values

Predicted optimal
value
21.4549
0.5261
1.1415

Experimental Value(Average of repeated Three

experiments)
22.104
0.5491
1.15

Page
64

% of Error
3.02
4.37
0.74

CHAPTER FIVE
CONCLUDING REMARK

The work is carried out to estimate the optimal solutions of ROTORY EDM parameter
that lead to the minimum surface value, minimum electrode wear rate and maximum
materrial removal rate by using genetic algorithm technique. . The work mainly
focuses on the MRR, EWR and SR performance; it has been found that this issue has
not yet been taken up by other researchers. So, the assumption could be that this work
gives a new contribution to the optimization of rotory EDM . From the entire work
following conclusions are drawn
1. Traditional optimization methods were found unsuitable to solve complicated and
implicit functions of the decision variables therefore real coded version of the GA was
used for solving the formulated optimization models.
2. The implementation of genetic algorithm in optimization of machining processes is
very effective, economic and efficient technique. The optimized condition that gives
better performance when the various response were considered simultaneously.
3. From Table 4.4 and Table 4.5 it is clear that this study has found that the GA
technique has been the effective technique for estimating the better results in terms of
the best point and average minimum and maximum values of cutting force component
compared to the experimental and regression results.
4. It has been also discovered that the optimal value for each of the polishing condition
recommended by GA which leads to the minimum SR and EWR also maximum MRR
values are satisfied by the cutting conditions range applied in the real experiment.

Page
65

REFERENCES
1. Rao S. S., Engineering optimization theory and practice . Third Edition, New
Delhi:New Age International (P) Ltd., (1996).
2. Tom V. Mathew, "Genetic algorithm".
3.N.M. Abbas, D.G. Solomon, M.F. Bahari, A review on current research trends in
electrical discharge machining, (EDM) International Journal of Machine Tools &
Manufacture.
4. M. Bayramoglu and A.W. Duffill,Manufacturing linear and circular contours
using CNC EDM and frame type tools, International Journal of Machine Tools and
Manufacture, Volume 35, Issue 8, 1995, 1125-1136
5. D.S. Bilgi. V.K. Jain. R. Shekhar. A.V. Kulkarni, Hole quality and interelectrode
gap dynamics during pulse current electrochemical deep hole drilling, SpringerVerlag London Limited 2006
6. S.K. Chak & P.V. Rao, The drilling of Al2O3 using a pulsed DC supply with a
rotary, abrasive electrode by the electrochemical discharge process, Int J Adv Manuf
Technol DOI 10.1007/s00170-007-1263-x
7. K.D. Chattopadhyay, P.S. Satsangi, S. Verma and P. C. Sharma, Analysis of
rotary electrical discharge machining characteristics in reversal magnetic field for
copper-en8 steel, system Int J Adv Manuf Technol DOI 10.1007/s00170-007-1149-y
8. K.D. Chattopadhyay, S. Verma, P.S. Satsangi and P.C. Sharma, Development of
empirical model for different process parameters during rotary electrical discharge
machining of coppersteel (EN-8) system, 2008.
9. S.L. Chen, S.F. Hsieh, H.C. Lin, M.H. Lin and J.S. Huang, Electrical discharge
machining of a NiAlFe ternary shape memory alloy, Journal of Alloys and
Compounds, available online 7 October 2007

Page
66

10. S.L. Chen, M.H. Lina, S.F. Hsiehb, S.Y. Chioub, The characteristics of cutting
pipe mechanism with multi-electrodes in EDM, journal of materials processing
technology (2007)
11. C. Dhavamani, T. Alwaesamy, " review on optimization of machining operation",
Vol. 3. No. 3. May, 2011, II Part, International Journal Of Academic Research.
12. Dereli, T. and Filiz, H.I, Optimization of process planning functions by genetic
algorithm . Computers and Industrial Engineering, Vol. 36, pp 281-308, (1999).
13. Aman Agrawal, Hari Singh, "Optimization of machining techniques- A
retrorespective and literature review.

Page
67