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EN
The use of form tools is growing in industry, owing to their inherent advantage of improving productivity. However, the accurate formation of form tool profile is a really tedious task. In this research work, wire electric discharge machining (WEDM) process has been used for the generation of a form tool. Pulse on-time, pulse off-time, servo voltage, wire tension, flushing pressure have been considered as input parameters, whereas tool geometry (clearance angle, included angle), surface roughness and material removal rate are the selected responses. Response surface methodology (RSM) (Box Bhenken experimental design) technique has been used for design of experiments. Analysis of Variance (ANOVA) has shown that pulse on-time and pulse off-time are the two influential control factors for material removal rate (MRR), surface roughness (Ra), clearance angle and included angle. Contour plot analysis has been performed to find out the optimal ranges of the most influential control factors for each response characteristics.
EN
Every manufacturing or production unit should concern about the quality of the product. Apart from quality, there exists other criterion, called productivity which is directly proportional to the profit level. Every manufacturing industry aims at producing a large number of products in relatively lesser time. In any machining process, it is most important to determine the optimal settings of machining parameters aiming at reduction of production costs and achieving the desired product quality. If the problem is related to a single quality attribute then it is called single objective optimization. If more than one attribute comes into consideration it is very difficult to select the optimal setting which can achieve all quality requirements simultaneously. In this work, EN-24 alloy steel work pieces were turned on Computer Numerical Controlled (CNC) lathe by using Cemented carbide tool (coated). The influence of four cutting parameters, cutting speed, feed rate, depth of cut, and tool nose radius on minuscule surface roughness and material removal rate (MRR) were analyzed on the basis of Response Surface Methodology approach. The experimental results were collected by following the Taguchi’s L16 mixed Orthogonal Array design.
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