Faculty Publications

Permanent URI for this communityhttps://idr.nitk.ac.in/handle/123456789/18736

Publications by NITK Faculty

Browse

Author: search.filters.author.Manoj, I.V.Subject: search.filters.subject.Electric discharge machining

Search Results

Now showing 1 - 7 of 7
  • No Thumbnail Available
    Item
    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.
  • No Thumbnail Available
    Item
    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.
  • No Thumbnail Available
    Item
    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.
  • No Thumbnail Available
    Item
    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.
  • No Thumbnail Available
    Item
    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.
  • No Thumbnail Available
    Item
    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.
  • No Thumbnail Available
    Item
    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.