INVESTIGATION OF MACHINING

PARAMETERS FOR THE MULTIPLE-

RESPONSE OPTIMIZATION OF MICRO
ELECTRODISCHARGE MILLING
PRESENTED BY:-RASHMIRANJAN SETHY
M-TECH 1ST YR
ROLL NO:-223ME2430
SYSTEM SIMULATION LAB
 INTRODUCTION:-
1. THE FOCUS IS ON THE IMPORTANCE OF MINIATURIZATION IN
VARIOUS TECHNOLOGICAL FIELDS, SUCH AS ELECTRONICS,
BIOMEDICAL ENGINEERING, AEROSPACE, AND MILITARY
APPLICATIONS.
2. IT DISCUSSES THE CHALLENGES IN MINIATURIZATION AND THE
LIMITATIONS OF EXISTING FABRICATION TECHNIQUES,
EMPHASIZING THE NEED FOR SIMPLER AND MORE COST-EFFECTIVE
PROCESSES.
3. IT INTRODUCES MICRO ELECTRODISCHARGE (ED) MILLING AS A
PROMISING METHOD FOR CREATING COMPLEX MICRO-SCALE
FEATURES IN A WIDE RANGE OF MATERIALS, HIGHLIGHTING ITS
ADVANTAGES OVER TRADITIONAL TECHNIQUES LIKE DIE-SINKING
MICRO EDM. VARIOUS PROCESS PARAMETERS AFFECTING MICRO
ED MILLING, SUCH AS DISCHARGE ENERGY, TOOL WEAR, AND
SCHEMATIC OF
CHOICE OF DIELECTRIC FLUID, ARE DISCUSSED. THE PASSAGE ALSO MICRO ED
MENTIONS THE LACK OF COMPREHENSIVE UNDERSTANDING OF
THESE PARAMETERS DUE TO THE RELATIVELY NEW NATURE OF
MILLING
MICRO ED MILLING.
4. IT CONCLUDES BY NOTING THE INFLUENCE OF FACTORS LIKE
DISCHARGE ENERGY, FEED RATE, TOOL POLARITY, AND DIELECTRIC
FLUID ON PARAMETERS LIKE SURFACE ROUGHNESS AND MATERIAL
MILLING
 IN MICRO ED MILLING, THE MATERIAL IS ERODED BY NONCONTACT
THERMOELECTRICAL PROCESS, WHICH IS SIMILAR TO MICRO EDM.
 A SERIES OF DISCRETE SPARKS OCCUR BETWEEN THE WORKPIECE
AND THE ROTATING TOOL ELECTRODE. THE WORKPIECE AND TOOL
ARE IMMERSED IN A DIELECTRIC FLUID.
 MICRO ED MILLING HAS A NUMBER OF PROCESS PARAMETERS, WHICH
ARE INFLUENTIAL ON THE MACHINING PERFORMANCE.
 IT WAS ALSO OBSERVED THAT TOOL WEAR WAS INCREASING WITH
FEED RATE BUT AFTER REACHING THE PEAK IT STARTED
DECREASING.
DESIGN OF EXPERIMENT METHOD
FOLLOW-

• FACTORIAL DESIGN
• DEFINE CUSTOM FACTORIAL
• EXPERIMENTAL RUN TABLE
• ANALYSIS OF EXEPERIMENT
• INTERSECTION EFFECT WITH GRAPH
• REGRETION EQUATION FOR RESPONSE
 EXPERIMENTAL WORKPIECE AND
DESIGN TOOL MATERIALS

 The experiment was designed based on • Beryllium–copper (Be–cu) Alloy (Be=0.4%,

Ni=1.8%, Cu= 97.8%), Which Is Also Known
three-level full factorial statistical model, As Protherm, Was Selected As The
which was chosen to observe and analyze the Workpiece Material. It Possesses Very High
individual influences as well as the Thermal Conductivity (245 Wm−1 °C−1 ),
High Temperature Resistance, And High
interaction effects of the three process
Corrosion Resistance. These Features Enable
parameters on Ra, Ry , TWR, and MRR. A It To Become A Suitable Mold Material. As
total number of 32 experiments was The Tool Electrode Material, Tungsten (W)
conducted, which includes five repeated Was Chosen Because Of Its Low Wear Rate.
The Electrode Diameter Was 0.5 Mm.
experiments at the same middle values of the
parameters.
FACTORS NAME AND LEVELS OF THE
FACTORS

 FEED RATE 3 LEVELS

 CAPACITANC  LEVEL 1
E  LEVEL 2
 VOLTAGE  LEVEL 3
EXPERIMENTAL DESIGN TABLE:-
EXPERIMENTAL RUN TABLE:-
SL.NO FEED RATE CAPACITANCE VOLTAGE Ra Ry TWR MRR
1 2 0.1 120 19 1.81 0.227 0.07
2 6 10 100 0.53 4.05 0.216 0.13
3 2 10 80 0.44 3.23 0.182 0.06
4 2 10 100 0.53 3.99 0.239 0.1
5 2 0.1 100 0.05 0.49 0.165 0.03
6 2 1 120 0.05 0.44 0.198 0.06
7 6 0.1 120 0.08 1.23 0.166 0.1
8 4 0.1 120 0.17 1.22 0.086 0.36
9 4 0.1 80 0.04 0.35 0.044 0.07
10 2 0.1 80 0.04 0.31 0.121 0.02
11 6 1 100 0.18 1.38 0.186 0.14
12 6 0.1 100 0.06 0.54 0.157 0.09
13 6 10 80 0.48 3.53 0.22 0.11
14 4 10 80 0.44 3.21 0.089 0.1
15 6 1 80 0.1 0.89 0.165 0.09
16 2 1 100 0.19 1.28 0.194 0.06
17 4 1 80 0.12 0.91 0.066 0.09
18 6 0.1 80 0.04 0.36 0.133 0.09
19 6 1 120 0.18 1.37 0.198 0.14
20 2 1 80 0.1 0.78 0.154 0.04
21 4 1 100 0.17 1.2 0.065 0.16
22 6 10 120 0.54 3.77 0.247 0.15
23 4 10 120 0.62 3.79 0.128 0.41
24 2 10 120 0.56 3.11 0.261 0.16
25 4 1 120 0.17 1.22 0.086 0.36
26 4 0.1 100 0.05 0.4 0.049 0.09
27 4 10 100 0.54 4.08 0.098 0.35
ANALYSIS OF EXPERIMENTAL RUNS USING
MINITAB:-
SL.NO FEED RATE CAPACITANCE VOLTAGE Ra Ry TWR MRR StdOrder_1RunOrder_1Blocks_1 PtType_1
1 2 0.1 120 19 1.81 0.227 0.07 1 1 1 1
2 6 10 100 0.53 4.05 0.216 0.13 2 2 1 1
3 2 10 80 0.44 3.23 0.182 0.06 3 3 1 1
4 2 10 100 0.53 3.99 0.239 0.1 4 4 1 1
5 2 0.1 100 0.05 0.49 0.165 0.03 5 5 1 1
6 2 1 120 0.05 0.44 0.198 0.06 6 6 1 1
7 6 0.1 120 0.08 1.23 0.166 0.1 7 7 1 1
8 4 0.1 120 0.17 1.22 0.086 0.36 8 8 1 1
9 4 0.1 80 0.04 0.35 0.044 0.07 9 9 1 1
10 2 0.1 80 0.04 0.31 0.121 0.02 10 10 1 1
11 6 1 100 0.18 1.38 0.186 0.14 11 11 1 1
12 6 0.1 100 0.06 0.54 0.157 0.09 12 12 1 1
13 6 10 80 0.48 3.53 0.22 0.11 13 13 1 1
14 4 10 80 0.44 3.21 0.089 0.1 14 14 1 1
15 6 1 80 0.1 0.89 0.165 0.09 15 15 1 1
16 2 1 100 0.19 1.28 0.194 0.06 16 16 1 1
17 4 1 80 0.12 0.91 0.066 0.09 17 17 1 1
18 6 0.1 80 0.04 0.36 0.133 0.09 18 18 1 1
19 6 1 120 0.18 1.37 0.198 0.14 19 19 1 1
20 2 1 80 0.1 0.78 0.154 0.04 20 20 1 1
21 4 1 100 0.17 1.2 0.065 0.16 21 21 1 1
22 6 10 120 0.54 3.77 0.247 0.15 22 22 1 1
23 4 10 120 0.62 3.79 0.128 0.41 23 23 1 1
24 2 10 120 0.56 3.11 0.261 0.16 24 24 1 1
25 4 1 120 0.17 1.22 0.086 0.36 25 25 1 1
26 4 0.1 100 0.05 0.4 0.049 0.09 26 26 1 1
27 4 10 100 0.54 4.08 0.098 0.35 27 27 1 1
FACTORIAL REGRESSION OF (RA) AND
(RY):-
FACTORIAL REGRESSION OF (TWR) AND
(MRR)
SURFACE ROUGHNESS:- Ry:-
The model was developed for 95% level of
confidence. The model F value of 213.06
implies the model is significant. There is
almost no influence, 0.01%, of noise on the
model developed. By checking F value and P
value, it is clearly seen that factor B Maximum peak to valley
(capacitance), factor C (voltage), and factor roughness height
B2 are most influential on Ra. The P value of
each of these factors indicates the confidence
level is more than 99.00%, which shows their
very strong influence.
 TOOL WEAR
RATIO(TWR):- MATERIAL
REMOVAL RATE(MRR):-
• There is less than 0.01% chance that
this F value occurred due to noise. • MRR increases with the increase in
• TWR decreases with the increase in
feed rate. For further increase in
feed rate. For further increase in feed
feed rate, MRR starts falling
rate, TWR starts rising.
slightly.
• The unwanted sparks erode materials
• The spark discharge results in
from the tool electrode, which results
reduced MRR.
in high tool wear. Thus, higher • The spark energy is more involved
capacitance results in higher TWR.
in material erosion, which increases
MRR till it reaches to the optimum.
GHRAPS:-
CONTINUE:-
REGRESSION EQUATION
MRR= 0.1344 - 0.06778 FEED RATE_2 + 0.08667 FEED RATE_4 - 0.01889 FEED RATE_6- 0.03222 CAPACITANCE_0.1 - 0.007778 CAPACITANCE_1.0 + 0.04000 CAPACITANCE_10.0- 0.06000 VOLTAGE_80
- 0.006667 VOLTAGE_100 + 0.06667 VOLTAGE_120+ 0.005556 FEED RATE*CAPACITANCE_2 0.1 - 0.005556 FEED RATE*CAPACITANCE_2 1.0- 0.000000 FEED RATE*CAPACITANCE_2 10.0
- 0.01556 FEED RATE*CAPACITANCE_4 0.1- 0.01000 FEED RATE*CAPACITANCE_4 1.0 + 0.02556 FEED RATE*CAPACITANCE_4 10.0+ 0.01000 FEED RATE*CAPACITANCE_6 0.1
+ 0.01556 FEED RATE*CAPACITANCE_6 1.0- 0.02556 FEED RATE*CAPACITANCE_6 10.0 + 0.03333 FEED RATE*VOLTAGE_2 80+ 0.003333 FEED RATE*VOLTAGE_2 100 - 0.03667 FEED RATE*VOLTAGE_2
120- 0.07444 FEED RATE*VOLTAGE_4 80 - 0.01444 FEED RATE*VOLTAGE_4 100+ 0.08889 FEED RATE*VOLTAGE_4 120 + 0.04111 FEED RATE*VOLTAGE_6 80+ 0.01111 FEED RATE*VOLTAGE_6 100
- 0.05222 FEED RATE*VOLTAGE_6 120+ 0.01778 CAPACITANCE*VOLTAGE_0.1 80 - 0.02556 CAPACITANCE*VOLTAGE_0.1 100+ 0.007778 CAPACITANCE*VOLTAGE_0.1
120+ 0.006667 CAPACITANCE*VOLTAGE_1.0 80+ 0.000000 CAPACITANCE*VOLTAGE_1.0 100 - 0.006667 CAPACITANCE*VOLTAGE_1.0 120- 0.02444 CAPACITANCE*VOLTAGE_10.0 80
+ 0.02556 CAPACITANCE*VOLTAGE_10.0 100- 0.001111 CAPACITANCE*VOLTAGE_10.0 120 -0.01111 FEED RATE*CAPACITANCE*VOLTAGE_20.180+ 0.01889 FEED RATE*CAPACITANCE*VOLTAGE_2 0.1
100- 0.007778 FEED RATE*CAPACITANCE*VOLTAGE_2 0.1 120+ 0.006667 FEED RATE*CAPACITANCE*VOLTAGE_2 1.0 80+ 0.01000 FEED RATE*CAPACITANCE*VOLTAGE_2 1.0
100- 0.01667 FEED RATE*CAPACITANCE*VOLTAGE_2 1.0 120+ 0.004444 FEED RATE*CAPACITANCE*VOLTAGE_2 10.0 80- 0.02889 FEED RATE*CAPACITANCE*VOLTAGE_2 10.0 100
+ 0.02444 FEED RATE*CAPACITANCE*VOLTAGE_2 10.0 120+ 0.01333 FEED RATE*CAPACITANCE*VOLTAGE_4 0.1 80- 0.03667 FEED RATE*CAPACITANCE*VOLTAGE_4 0.1
100+ 0.02333 FEED RATE*CAPACITANCE*VOLTAGE_4 0.1 120+ 0.01444 FEED RATE*CAPACITANCE*VOLTAGE_4 1.0 80- 0.02222 FEED RATE*CAPACITANCE*VOLTAGE_4 1.0
100+ 0.007778 FEED RATE*CAPACITANCE*VOLTAGE_4 1.0 120- 0.02778 FEED RATE*CAPACITANCE*VOLTAGE_4 10.0 80+ 0.05889 FEED RATE*CAPACITANCE*VOLTAGE_4 10.0
100- 0.03111 FEED RATE*CAPACITANCE*VOLTAGE_4 10.0 120 0.002222 FEED RATE*CAPACITANCE*VOLTAGE_6 0.1 80+ 0.01778 FEED RATE*CAPACITANCE*VOLTAGE_6 0.1 100
- 0.01556 FEED RATE*CAPACITANCE*VOLTAGE_6 0.1 120- 0.02111 FEED RATE*CAPACITANCE*VOLTAGE_6 1.0 80
+ 0.01222 FEED RATE*CAPACITANCE*VOLTAGE_6 1.0 100+ 0.008889 FEED RATE*CAPACITANCE*VOLTAGE_6 1.0 120
+ 0.02333 FEED RATE*CAPACITANCE*VOLTAGE_6 10.0 80- 0.03000 FEED RATE*CAPACITANCE*VOLTAGE_6 10.0 100
+ 0.006667 FEED RATE*CAPACITANCE*VOLTAGE_6 10.0 120
 MULTIPLE RESPONSE OPTIMAZATION:-

• IT IS COMPLICATED TO FIND PROCESS

PARAMETERS THAT
SIMULTANEOUSLY MAXIMIZE OR
MINIMIZE ALL THE RESPONSES AS
DESIRED.
• THE METHOD FINDS OPERATING
CONDITIONS, E.G., FEED RATE,
CAPACITANCE, AND VOLTAGE, THAT
PROVIDE THE “MOST DESIRABLE”
VALUES OF THE RESPONSES, E.G., RA,
RY , TWR, AND MRR.
CONCLUSION:-

This paper discusses the selection

of micro ED milling parameters
for the optimization of Ra, Ry ,
TWR, and MRR. Three-level full
factorial experimental design was
used for the statistical analysis.
THANKYOU