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A novel optimization algorithm on surface roughness of WEDM on titanium hybrid composite

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Abstract

Titanium based alloys and composites have excellent strength and stability in high thermal condition, excellent resistance to creep, wear and corrosion, light weight and bio-compatible properties and are extensively used in defence, aerospace, spacecrafts, marine, automobile, sports and bio-medical applications. This paper presents an investigation based on a novel optimization algorithm called desirable grey relational analysis (DGRA) where experimental analysis is done on wire electro-discharge machining (WEDM) of a developed novel titanium hybrid composite having enhanced corrosion resistance, wear resistance, improved tribological and biocompatible properties than pure titanium, fabricated by laser engineered net shaping (LENS) process varying peak current (Ip) and pulse duration (PD) as main input process parameters. A mathematical model is proposed based on 2 factors 4 levels design of experiments on output response like surface roughness (SR) and satisfactory results are obtained and authenticated by the confirmatory test. Deionized water is used as dielectric medium. Diffused zinc-coated brass wire is used as tool electrode. SR enhances with the enhancement of Ip but reduces with PD. The process model is prepared and the optimum process parameters are hence determined. The best SR obtained experimentally is 1.31 µm (Ip, 3A, PD, 4 µs). One optimized solution is obtained where Ip is 4.666 A, PD is 17.092 µs, SR is 1.742 µm, standard error (StdErr) of Design is 0.049 and Desirability is 0.900. The novelty lies in the combination of desirability function and grey relational analysis where experimental SR measured at optimized condition gets improved by 2.78% by desirability approach and further improves to 7.29% when predicted with DGRA.

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Abbreviations

THC:

Titanium hybrid composite

DGRA:

Desirable grey relational analysis

WEDM:

Wire electro-discharge machining

LENS:

Laser engineered net shaping

Ip:

Peak current

PD:

Pulse duration

SR:

Surface roughness

RSM:

Response surface methodology

BBD:

Box–Behnken design

MRR:

Material removal rate

WW:

Wire wear

DOE:

Design of experiments

D:

Overall desirability function

ANOVA:

Analysis of variance

DGRC:

Desirable grey relational coefficient

DGRG:

Desirable grey relational grade

DGRGm :

Mean of DGRG

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Authors and Affiliations

  1. Department of Mechanical Engineering, MCKV Institute of Engineering, 243 G.T. Road (N), Liluah, Howrah, West Bengal, 711204, India

    Soutrik Bose

  2. Department of Mechanical Engineering, Jadavpur University, 188 Raja S.C. Mallick Road, Kolkata, West Bengal, 700032, India

    Soutrik Bose & Titas Nandi

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  1. Soutrik Bose
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  2. Titas Nandi
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Correspondence to Soutrik Bose.

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Bose, S., Nandi, T. A novel optimization algorithm on surface roughness of WEDM on titanium hybrid composite. Sādhanā 45, 236 (2020). https://doi.org/10.1007/s12046-020-01472-5

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  • DOI: https://doi.org/10.1007/s12046-020-01472-5

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