Browsing by Author "Manoj, I.V."

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Artificial neural network-based prediction assessment of wire electric discharge machining parameters for smart manufacturing
(De Gruyter Open Ltd, 2023) Manoj, I.V.; Narendranath, S.; Mashinini, P.M.; Soni, H.; Rab, S.; Ahmad, S.; Hayat, A.
Artificial intelligence (AI), robotics, cybersecurity, the Industrial Internet of Things, and blockchain are some of the technologies and solutions that are combined to produce "smart manufacturing,"which is used to optimize manufacturing processes by creating and/or accepting data. In manufacturing, spark erosion technique such as wire electric discharge machining (WEDM) is a process that machines different hard-to-cut alloys. It is regarded as the solution for cutting intricate parts and materials that are resistant to conventional machining techniques or are required by design. In the present study, holes of different radii, i.e. 1, 3, and 5 mm, have been cut on Nickelvac-HX. Tapering in WEDM is a delicate process to avoid disadvantages such as wire break, wire bend, wire friction, guide wear, and insufficient flushing. Taper angles viz. 0°, 15°, and 30° were obtained from a unique fixture to get holes at different angles. The study also shows the influence of taper angles on the part geometry and area of the holes. Next, the artificial neural network (ANN) technique is implemented for the parametric result prediction. The findings were in good agreement with the experimental data, supporting the viability of the ANN approach for the evaluation of the manufacturing process. The findings in this research provide as a reference to the potential of AI-based assessment in smart manufacturing processes and as a design tool in many manufacturing-related fields. © 2023 the author(s), published by De Gruyter.
Effect of Profile Geometry and Cutting Speed Override Parameter on Profiling Speed During Tapering Using Wire Electric Discharge Machining
(Springer Science and Business Media Deutschland GmbH, 2022) Manoj, I.V.; Narendranath, S.
The oblique/tapered form of precise components has many applications like dies, nozzles, inserts, cutting tools, and other components. Wire electric discharge machining is an erosion technique that helps in precise machining of hard materials. In the present study, basic profiles were machined using a novel slant-type fixture to achieve a slant surface on Hastelloy X. The shapes like triangle, square, and circle are machined at different slant angles, namely 0Â° and 30Â°. This paper aims to study the effects of the cutting speed override parameter and profile geometry on profiling speed of machined profiles. The basic shapes of 1, 3, and 5Â mm sides were machined. The cutting speed override parameter affected the most on profiling speed in both the angles irrespective of profiles. The profile geometry also affects the profiling speed although the machining parameters were maintained constant. Â© 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
Evaluation of WEDM performance characteristics and prediction of machining speed during taper square profiling on Hastelloy-X
(Taylor and Francis Ltd., 2023) Manoj, I.V.; Narendranath, S.
Hastelloy-X is one of the wrought nickel-base superalloy comprising of oxidation resistance and high-temperature strength. Wire electric discharge machining process is the favoured technique for precise component fabrication of such materials. Apart from precision the most essential aspect with surface integrity and cutting velocity in manufacturing. This investigation deals with the effects of cutting speed override, corner dwell time, wire guide distance and wire offset on taper profile response characteristics. The variation of these parameters is studied by machining a simple square profile at 0°, 15° and 30° taper angles. It is observed that as the taper angle gets increased, both the machined errors at corners and machined roughness increased although the machining speed gets reduced. The recast layer and micro-hardness are explored for the taper square profile components. It is observed that the recast layer thickness was least for 30° taper profiles indicating least thermal degradation which was validated by micro-hardness. It was established that in a machined profile, that corners possessed lower hardness than the edges. The micro-hardness of inner profile corners was found to be lower than outer profile corners. Adaptive neuro-fuzzy interference system is better prediction computing method having least error ranging from 0–4.89%. In conclusion, the machining speed and taper angle also contribute to the output characteristics in wire electric discharge taper profiling. © 2021 Engineers Australia.
Examination of Machining Parameters and Prediction of Cutting Velocity and Surface Roughness Using RSM and ANN Using WEDM of Altemp HX
(Hindawi Limited, 2022) Manoj, I.V.; Soni, H.; Narendranath, S.; Mashinini, P.M.; Kara, F.
The Altemp HX is a nickel-based superalloy having many applications in chemical, nuclear, aerospace, and marine industries. Machining such superalloys is challenging as it may cause both tool and surface damage. WEDM, a non-contact machining technique, can be employed in the machining of such alloys. In the present study, different input parameters which include pulse on time, wire span, and servo gap voltage were investigated. The cutting velocity, surface roughness, recast layer, and microhardness variations were examined on the WEDMed surface. The genetic algorithm was used to optimize the cutting velocity and surface roughness, thereby improving the overall quality of the product. The highest recast layer values were recorded as 25.8 μm, and the lowest microhardness was 170 HV. Response surface methodology and artificial neural network were employed for the prediction of cutting velocity and surface roughness. Artificial neural network prediction technique was the most efficient method for the prediction of response parameters as it predicted an error percentage lesser than 6%. © 2022 I. V. Manoj et al.
Influence of machining parameters on taper square areas during slant type taper profiling using wire electric discharge machining
(IOP Publishing Ltd, 2021) Manoj, I.V.; Narendranath, S.
The oblique/tapered machining is a unique method in wire electric discharge machining to get taper profiles difficult to machine materials. These profiles have many applications like dies, nozzles, inserts, cutting tools and other components. In the present study, a simple square profile is machined using a slant type fixture to achieve a tapered profile made of Hastelloy X. A simple square is machined at different slant angles to get a 0 , 15 and 30 tapered profiles. This paper aims to study the effects of the machining parameters like wire guide distance, wire offset, corner dwell time and cutting speed override on the area of machined profiles. Both scanning electron microscope and coordinate measuring machine were used to measure the areas of 1mm and 5mm. It is observed that as the wire guide distance and cutting speed override increases the area decreases. Whereas in case of wire offset, as offset increases the areas also increase and corner dwell time doesn't affect on the area. As the angle increased the area also increased leading to bigger taper profiles. Â© Published under licence by IOP Publishing Ltd.
Investigation of cutting speed, recast layer and micro-hardness in angular machining using slant type taper fixture by WEDM of Hastelloy X
(Elsevier Ltd, 2019) Joy, R.; Manoj, I.V.; Narendranath, S.
Wire electric discharge machining (WEDM) is a thermo-electric spark erosion process that can machine any difficult to cut materials. Taper cutting in WEDM is a unique feature that has many problems such as taper angular inaccuracies, wire cut and distribution of dielectric fluid during machining. In the present research work, angular machining is performed for generating a tapered component using a novel slant type taper fixture which overcomes the disadvantages of taper cutting in WEDM. The machining was performed on Hastelloy X at various angles namely 0Â°, 30Â° and 60Â° with different parameters in the machining range. The behaviour of cutting speeds for Taguchi's L9 set of experiments at 0Â°, 30Â° and 60Â° angle of tilt in machining was reported. The cutting speed is ranging from 0.16 mm/min to 2.49 mm/min during angular machining. From the SEM micrographs, the highest average recast layer thickness for highest cutting speed parameter was 26.4 Î¼m at 0Â° and for the lowest cutting speed parameter, it was measured 6.4 Î¼m lowest at 60Â° compared to the remaining angle of cut. The variation of micro-hardness at 0Â°, 30Â° and 60Â° tapered components at the highest cutting speed parameter were measured using Vickers micro-hardness test. The lowest Vickers hardness was found to be 167Hv at 0Â°. However further it is increased to 173Hv and 180Hv at 30Â° and 60Â° angle of cut respectively. Â© 2019 Elsevier Ltd.
Investigation of machining parameters on corner accuracies for slant type taper triangle shaped profiles using WEDM on Hastelloy X
(2019) Manoj, I.V.; Joy, R.; Narendranath, S.; Nedelcu, D.
Wire electro-discharge machining (WEDM) is a widely used machining process for machining of difficult to cut materials, which are used in precision profile applications like dies, metal stampings, and gas turbine parts. In the present research work, a new slant type taper fixture was used to obtain angular machining of triangular shape slots of sides 1mm, 3mm and 5mm machined both in 0� and 30� as slant angles on Hastelloy X. The corner radius and corner errors were investigated for different machining parameters like corner dwell time (CDT), offset distance (WO), wire guide distance (WGD) and cutting speed override (CSO) using L16 orthogonal array for both the slant angles. SEM micrographs indicated that corners were with lower radii at 30� than in 0� slant profiles, at lowest and highest cutting speeds. The main effects plot showed that the corner radius increases with the increase in wire offset and wire guide distance parameters. The increase in corner dwell time has an adverse effect on the corner radius. The triangles were machined at different cutting speeds from 0.47 to 1.51 mm/min with various parameters; it was observed that as the corner radius decreases the corner error also reduces. However, the corner radius and corner error can be minimized by selecting an optimized cutting parameter. � 2019 Published under licence by IOP Publishing Ltd.
Investigation of machining parameters on corner accuracies for slant type taper triangle shaped profiles using WEDM on Hastelloy X
(Institute of Physics Publishing helen.craven@iop.org, 2019) Manoj, I.V.; Joy, R.; Narendranath, S.; Nedelcu, D.
Wire electro-discharge machining (WEDM) is a widely used machining process for machining of difficult to cut materials, which are used in precision profile applications like dies, metal stampings, and gas turbine parts. In the present research work, a new slant type taper fixture was used to obtain angular machining of triangular shape slots of sides 1mm, 3mm and 5mm machined both in 0Â° and 30Â° as slant angles on Hastelloy X. The corner radius and corner errors were investigated for different machining parameters like corner dwell time (CDT), offset distance (WO), wire guide distance (WGD) and cutting speed override (CSO) using L16 orthogonal array for both the slant angles. SEM micrographs indicated that corners were with lower radii at 30Â° than in 0Â° slant profiles, at lowest and highest cutting speeds. The main effects plot showed that the corner radius increases with the increase in wire offset and wire guide distance parameters. The increase in corner dwell time has an adverse effect on the corner radius. The triangles were machined at different cutting speeds from 0.47 to 1.51 mm/min with various parameters; it was observed that as the corner radius decreases the corner error also reduces. However, the corner radius and corner error can be minimized by selecting an optimized cutting parameter. Â© 2019 Published under licence by IOP Publishing Ltd.
Investigation on the Effect of Variation in Cutting Speeds and Angle of Cut During Slant Type Taper Cutting in WEDM of Hastelloy X
(Springer, 2020) Manoj, I.V.; Joy, R.; Narendranath, S.
Nickel-based superalloys are classified under difficult to machine materials due to its higher affinity to tool materials and low thermal diffusivity. Wire electric discharge machining (WEDM) is a spark eroding technique for precise machining of such superalloys with complex machining geometries. Tapering in WEDM has many disadvantages like wire break, angular inaccuracies and dielectric distribution for better surfaces. In this paper, a unique method was developed and employed to achieve taper surface by tilting the workpiece using a slant type taper fixture for machining of tapered surfaces. Different aspects like cutting thickness, surface roughness, slant angle, surface crack density and width of cut were examined for five distinct cutting speed parameters at different angles, namely 0°, 15°, 30°, 45° and 60°. In the present research work, Hastelloy X was machined using zinc-coated copper wire and cutting speed was ranged between 0.16 and 2.49 mm/min. The slant angle was observed to be independent of cutting speed, and it was influenced by wire vibration, manufacturing imprecisions of slant fixture. It was found that as the cutting speed increases, surface crack density and surface roughness also increase. It was observed that both the parameters increased with the increase in the angle of cut from 0° to 60° although the cutting speed decreased. © 2019, King Fahd University of Petroleum & Minerals.
Machining and forecasting of square profile areas using artificial neural modelling at different slant angles by WEDM.
(IOP Publishing Ltd, 2021) Manoj, I.V.; Narendranath, S.
Wire electric discharge machining non-conventional process that removes materials by thermal erosion. Tapering in WEDM has many applications in machining accurate geometric profiles. In the present investigation, a slant type taper machining was performed to produce taper profiles with the help of the slant fixture. The machining parameters such as wire guide distance, corner dwell time, wire offset and cutting speed override was employed to find the variation in the taper profile area. A simple square profile of 1mm, 3mm and 5mm was machined at different slant angles namely 0Â°, 15Â° and 30Â°. It was observed that each parameter yielded different profile areas. The artificial neural network was used for the forecasting the areas of 1mm, 3mm and 5mm square for different parameters. The optimum artificial neural network model was experimentally validated and the errors were ranging from 0-10%. Â© Published under licence by IOP Publishing Ltd.
Optimization and prediction of machining responses using response surface methodology and adaptive neural network by wire electric discharge machining of alloy-x
(Trans Tech Publications Ltd, 2021) Manoj, I.V.; Narendranath, S.; Pramanik, A.
Wire electric discharge machining non-contact machining process based on spark erosion technique. It can machine difficult-to-cut materials with excellent precision. In this paper Alloy-X, a nickel-based superalloy was machined at different machining parameters. Input parameters like pulse on time, pulse off time, servo voltage and wire feed were employed for the machining. Response parameters like cutting speed and surface roughness were analyzed from the L25 orthogonal experiments. It was noted that the pulse on time and servo voltage were the most influential parameters. Both cutting speed and surface roughness increased on increase in pulse on time and decrease in servo voltage. Grey relation analysis was performed to get the optimal parametric setting. Response surface method and artificial neural network predictors were used in the prediction of cutting speed and surface roughness. It was found that among the two predictors artificial neural network was accurate than response surface method. Â© 2021 Trans Tech Publications Ltd, Switzerland.
Optimization and Prediction of Responses Using Artificial Neural Network and Adaptive Neuro-Fuzzy Interference System during Taper Profiling on Pyromet-680 Using Wire Electric Discharge Machining
(Springer, 2023) Manoj, I.V.; Manjaiah, M.; Narendranath, S.
In the present study, taper cutting is performed with the aid of a uniquely designed fixture. This is attempted to avoid the difficulties in tapering using wire electric discharge machining like wire break, dimensional error, guide wear, non-uniform flushing and low surface quality. An investigation of output parameters was made during taper machining using a fixture. The cutting rate (CR) and surface roughness (SR) were considered for response surface optimization (RSM) as they were important response parameters that indicate the quality of a machined component. It is observed that servo gap voltage and pulse act contrastingly on the output parameters. For achieving a trade-off of input parameters with output responses, RSM optimization is selected during taper profiling. There were 3-5% variations for both CR and SR when compared to experimental and RSM optimal values. The tapered profile slots of different angles like 0°, 15° and 30° were machined on Pyromet-680 using optimal machining parameters. The effect of different profiling parameters like wire distance between guides (WD), dwell time (DT), profile offset (PO) and cutting speed override (CO) on output responses like CR and SR was analyzed. Adaptive neuro-fuzzy interference system (ANFIS) and artificial neural network (ANN) models have been established for the prediction of the output responses. The validation is performed by experimentation, and the prediction errors ranged from 0 to 5% for both the responses CR and SR in ANFIS models. So ANFIS models proved to be the most efficient as there is an improvement of 45-50% in prediction compared to ANN models. © 2022, ASM International.
Parametric Analysis and Response Surface Optimization of Surface Roughness and Cutting Rate in the Machining Using WEDM
(Springer Science and Business Media Deutschland GmbH, 2022) Manoj, I.V.; Narendranath, S.
Nickelvac HX is an amalgamation of nickel, chromium, iron, molybdenum etc. As nickel-based alloys have high-temperature strength they can be used in many applications like afterburners, blades of turbines, turbocharges, submarines parts etc. Wire electric discharge machining a non-contact spark machining was found to be the most precise machining process. Among the WEDM parameters, different process parameters like servo voltage, pulse on time, cutting speed override and pulse off time were employed for the examination. It was noticed that both response characteristics increased with the increase in cutting speed override and pulse on-time. In the case of servo voltage and pulse off time, as it was increased the cutting rate and surface roughness diminished. The effects of cutting rate on surface roughness and microhardness were analyzed. The response surface optimization was employed for optimizing surface roughness and cutting rate as it controls product quality. Â© 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
Performance of profile characteristics at different machining parameters during wire electric discharge slant type taper profiling on Nicrofer 4722
(Inderscience Publishers, 2024) Manoj, I.V.; SannaYellappa, N.
In the present study, a slant type taper fixture is employed to achieve taper machining by wire electric discharge machining. Machining parameters like wire distance between the guides (WD), wire offset (WO), corner-dwell time (CT) and cutting-speed override (CO) is used to produce tapered components at 0°, 15°, and 30° angles. It is observed that as the WD, CO and WO increases the profile roughness also increases. The profiling error (PE) increases with increasing WD and CO parameters due to the increase in wire lag phenomenon. However, the WO and CT parameters showed a decreasing effect on PE. There is a reduction observed in the recast layer thickness, as the taper angle increased. The apex of the triangular profile always tends to be shifted opposite to the wire direction of travel at 15° and 30° tapered components due to the electromagnetic force and decreased strength of the tapered corners. © © 2024 Inderscience Enterprises Ltd.
Slant type taper profiling and prediction of profiling speed for a circular profile during in wire electric discharge machining using Hastelloy-X
(SAGE Publications Ltd, 2021) Manoj, I.V.; Narendranath, S.
Hastelloy-X a nickel-based alloy used in nozzles, flame holders, turbine blades, turbocharges, jet engine tailpipes, afterburner components etc. having complex tapering profiles. Wire electric discharge machining proves to be the most beneficial machining technique as it provides required accuracy for the components. In the present research, a slant type taper fixture is employed for achieving taper angles as convention tapering have many hindrances like wire bend, angular inaccuracy, guide wear, insufficient flushing and wire breakage etc. and machining a simple circular profile on Hastelloy-X. The behaviour of different output parameters like profiling speed, surface roughness, profile areas, microhardness and recast layer were investigated for various input parameters for machined taper components at 0°, 15° and 30°. The cutting speed override parameter influenced most on the profiling speed and surface roughness. The wire offset parameter was found to be the most significant factor in the case of circular profile areas that were machined. The variation of different output parameters to profiling/cutting speed and taper angle was also highlighted. It is found the recast layer decreased which indicated lesser thermal degradation at higher taper angles at different profiling parameters. This is also validated by the microhardness where the machined surface hardness of taper angular profiles was found to be greater than the 0° profiles. The artificial neural networks and adaptive neuro-fuzzy interference system were used for the prediction of profiling speed. The adaptive neuro-fuzzy interference system was found better in prediction as the percentage error varies between 0–5 per cent. In conclusion, the profiling speed influences both on the accuracy and surface of machined taper circular profiles. © IMechE 2021.
Variation and artificial neural network prediction of profile areas during slant type taper profiling of triangle at different machining parameters on Hastelloy X by wire electric discharge machining
(SAGE Publications Ltd, 2020) Manoj, I.V.; Narendranath, S.
In the present research work, an in-house developed fixture is used to achieve taper profiles which avoids the disadvantages in convention tapering operation in wire electric discharge machining like wire bend, inaccuracies in taper, insufficient flushing, guide wear etc. A simple triangular profile was machined at 0°, 15° and 30° slant/taper angles. These taper profile areas are investigated for various machining parameters like wire guide distance, corner dwell time, wire offset and cutting speed override. It is observed that as the wire guide distance and cutting speed override increases, the profile area decreases. Whereas in case of wire offset, as offset increases the profile areas also increase. The corner dwell time parameter do not effect on the profile area. The taper profile areas measured highest at 30° followed by 15° and 0° slant angles. This is due to the workpiece placed at different angles during machining with the aid of fixture to obtain taper profile. The taper angle represents the angularity of slant triangular profiles. As the slant angle increases the variation in taper error also increases due to higher wire vibration. An artificial neural network model is developed for the prediction of these areas at a different slant angle. The model is validated experimentally where the errors in prediction ranged from 1% to 9%. In conclusion, it can be noticed that the machining parameters and slant angle influence on profiles irrespective of their dimensions. © IMechE 2020.
Wire Electric Discharge Machining at Different Slant Angles during Slant Type Taper Profiling of Microfer 4722 Superalloy
(Springer, 2022) Manoj, I.V.; Narendranath, S.
Wire electric discharge machining (WEDM) is nonconventional machining that provides machining solutions irrespective of the material hardness. In the present study, a simple profile was machined on Microfer 4722 at different slant angles using to know the effect of machining parameters. A unique method of obtaining taper components was employed by slant type taper fixture to avoid the disadvantages of the conventional method. The profiling speed, profile roughness, profiling error (Corner error), recast layer thickness, micro-hardness, microstructural and metallurgical changes of the machined component were investigated. As the taper of the component increases the profile roughness, corner error increases although profiling speed decreases. It is observed that recast layer thickness decreases as the taper of the component increases. A contrasting phenomenon is observed in the case of hardness at the WEDM surface. The metallurgical changes like the addition of Cu, Zn and O in the nickel-based alloy after machining from WEDM at different slant angles are highlighted. It is observed that residual stress decreased as the slant angles increased from 0° to 30° during slant type profiling. © 2021, ASM International.