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Selection of WEDM parameters to measure the performance and productivity of die steel grade D3 using GRA and fuzzy logic system

Sandeep Kumar (Department of Mechanical Engineering, Anna University, Chennai, India)
Dhanabalan S. (Department of Mechanical Engineering, M. Kumarasamy College of Engineering, Karur, India)

Grey Systems: Theory and Application

ISSN: 2043-9377

Article publication date: 17 June 2019

Issue publication date: 20 June 2019

Abstract

Purpose

The purpose of this paper is to examine the performance parameters of WEDM to improve the productivity and material removal rate (MRR) with a high surface finish of high chromium-high carbon dies steel.

Design/methodology/approach

The experiments were performed on AGIE CUT 220 CNC WEDM. High chromium-high carbon dies steel (D3) was used in the form of a rectangular plate. The workpiece and the brass wire having diameter ɸ 0.25 mm had linked up with +ve and –ve polarity in the DC power source, respectively. De-ionized water having a conductivity level of 0.6 µs/cm was used as the dielectric medium. The dielectric fluid was flushed from the top and bottom nozzles and material was submerged in the dielectric.

Findings

The WEDM process parameters for D3 die steel had optimized by using Grey relational analysis method couples with Taguchi method. The optimum solution has been calculated for MRR, cutting speed (Cs), machining time and surface roughness (SR) (Ra value). A fuzzy logic model using Matlab was developed for the prediction of performance parameters, namely MRR, cutting speed (Cs), machining time (M/c time) and SR with respect to changes in input parameters.

Research limitations/implications

The fuzzy model shows the 96.19 percent accuracy between the experimental values and the predicted values.

Practical implications

The optimized parameters by multi-parametric optimization method showed considerable improvement in the process and will facilitate the WEDM, tool and die industries, defense and aerospace industries to improve the productivity with the higher surface finish.

Originality/value

This manuscript represents valid work and the authors have no conflict of interests. The attained optimum outcomes had also been examined through a real experiment and established to be satisfactory.

Keywords

Acknowledgements

This manuscript represents valid work and the authors have no conflict of interests. The authors acknowledge that no funding has been granted/received for this research study and for preparation of this manuscript.

Citation

Kumar, S. and S., D. (2019), "Selection of WEDM parameters to measure the performance and productivity of die steel grade D3 using GRA and fuzzy logic system", Grey Systems: Theory and Application, Vol. 9 No. 3, pp. 336-355. https://doi.org/10.1108/GS-01-2019-0004

Publisher

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Emerald Publishing Limited

Copyright © 2019, Emerald Publishing Limited