Mandal Prosun, Mondal Suman, Cep Robert, Ghadai Ranjan Kumar
Department of Mechanical Engineering, National Institute of Technology Silchar, Silchar, Assam, India.
Department of Mechanical Engineering, Ramkrishna Mahato Government Engineering College, Purulia, West Bengal, India.
Sci Rep. 2024 Sep 5;14(1):20757. doi: 10.1038/s41598-024-71697-5.
Monel K-500 is a high-performance superalloy composed of nickel and copper, renowned for its exceptional strength, hardness, and resistance to corrosion. To machine this material more precisely and accurately, Electrical Discharge Machining (EDM) is one of the best choices. In EDM, material removal rate (MRR) and electrode wear rate (EWR) are crucial performance parameters that are often conflicting in nature. These parameters depend on several input variables, including peak current (Ip), pulse on time (Ton), duty cycle (Tau), and servo voltage (SV). Optimizing the EDM process is essential for enhancing performance. In this research, a set of experiments were conducted using EDM on Monel K500 alloy to determine the optimal process parameters. The Box-Behnken design was used to prepare the experimental design matrix. Utilizing the experimental data, a second-order mathematical model was developed using Response Surface Methodology (RSM). R value is found to be 99.40% and 96.60% for MRR and EWR RSM-based prediction model, respectively. High value of R is indicated is indicated good adequacy for prediction. The mathematical model further used in multi-objective dragonfly algorithm (MODA): a new meta-heuristic optimization technique to solve multi-objective optimization problem of EDM. The MODA is a very useful technique to achieve optimal solutions from the multi decision criteria. Utilizing this technique, a set of non-dominated solutions was obtained. Further, the TOPSIS method was used to determine the most desirable optimal solution, which was found to be 0.0135 mm/min for EWR and 6.968 mm/min for MRR. These results were obtained when the optimal process parameters were selected as Ip = 6 A, Ton = 200 µs, Tau = 12, and SV = 41.6 V. Operators can machine Monel K500 by selecting the above-mentioned optimal parameters to achieve the best performance.
蒙乃尔K - 500是一种由镍和铜组成的高性能超级合金，以其卓越的强度、硬度和耐腐蚀性而闻名。为了更精确地加工这种材料，电火花加工（EDM）是最佳选择之一。在电火花加工中，材料去除率（MRR）和电极磨损率（EWR）是关键的性能参数，它们在本质上往往相互冲突。这些参数取决于几个输入变量，包括峰值电流（Ip）、脉冲导通时间（Ton）、占空比（Tau）和伺服电压（SV）。优化电火花加工工艺对于提高性能至关重要。在本研究中，对蒙乃尔K500合金进行了一系列电火花加工实验，以确定最佳工艺参数。采用Box - Behnken设计来准备实验设计矩阵。利用实验数据，使用响应面方法（RSM）建立了二阶数学模型。基于RSM的MRR和EWR预测模型的R值分别为99.40%和96.60%。R值高表明预测的拟合度良好。该数学模型进一步用于多目标蜻蜓算法（MODA）：一种解决电火花加工多目标优化问题的新的元启发式优化技术。MODA是一种从多个决策标准中获得最优解的非常有用的技术。利用该技术，获得了一组非支配解。此外，采用TOPSIS方法确定最理想的最优解，发现EWR为0.0135 mm/min，MRR为6.968 mm/min。当选择最佳工艺参数为Ip = 6 A、Ton = 200 µs、Tau = 12和SV = 41.6 V时，得到了这些结果。操作人员可以通过选择上述最佳参数来加工蒙乃尔K500，以获得最佳性能。
