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Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production

Author

Listed:
  • Misbah Niamat

    (Mechanical Engineering Department, Muhammad Nawaz Sharif University of Engineering and Technology, Multan 66000, Pakistan)

  • Shoaib Sarfraz

    (Manufacturing Department, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield, Bedfordshire MK43 0AL, UK)

  • Wasim Ahmad

    (Faculty of Industrial Engineering, University of Engineering and Technology, Taxila 47080, Pakistan)

  • Essam Shehab

    (School of Engineering and Digital Sciences, Nazarbayev University, Nur-Sultan 010000, Kazakhstan)

  • Konstantinos Salonitis

    (Manufacturing Department, School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield, Bedfordshire MK43 0AL, UK)

Abstract

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The investigation, validation and deeper insights of developed models have been performed using ANOVA, validation experiments and microstructure analysis respectively. Pulse on time and current both appeared as the prominent process parameters having a significant influence on all three measured performance metrics. Multi-objective optimization has been performed in order to achieve sustainability by establishing a compromise between minimum quality, minimum cost and maximum productivity. Sustainability contour plots have been developed to select suitable desirability. The sustainability results indicated that a high level of 75.5% sustainable desirability can be achieved for AISI L3 tool steel. The developed models can be practiced on the shop floor practically to attain a certain desirability appropriate for particular machine limits.

Suggested Citation

  • Misbah Niamat & Shoaib Sarfraz & Wasim Ahmad & Essam Shehab & Konstantinos Salonitis, 2019. "Parametric Modelling and Multi-Objective Optimization of Electro Discharge Machining Process Parameters for Sustainable Production," Energies, MDPI, vol. 13(1), pages 1-20, December.
    • Handle: RePEc:gam:jeners:v:13:y:2019:i:1:p:38-:d:299996
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    References listed on IDEAS

    as
    1. Jack P. C. Kleijnen, 2015. "Response Surface Methodology," International Series in Operations Research & Management Science, in: Michael C Fu (ed.), Handbook of Simulation Optimization, edition 127, chapter 0, pages 81-104, Springer.
    2. Shoaib Sarfraz & Essam Shehab & Konstantinos Salonitis & Wojciech Suder, 2019. "Experimental Investigation of Productivity, Specific Energy Consumption, and Hole Quality in Single-Pulse, Percussion, and Trepanning Drilling of IN 718 Superalloy," Energies, MDPI, vol. 12(24), pages 1-25, December.
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    Cited by:

    1. Hadhami Ben Slama & Raoudha Gaha & Mehdi Tlija & Sami Chatti & Abdelmajid Benamara, 2023. "Proposal of a Combined AHP-PROMETHEE Decision Support Tool for Selecting Sustainable Machining Process Based on Toolpath Strategy and Manufacturing Parameters," Sustainability, MDPI, vol. 15(24), pages 1-20, December.

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