Abstract
In present work, micro-deep holes on AISI 304 stainless steel were drilled via electrical discharge machining (EDM) method. In the first phase of this work, the effect of test parameters on the drilling performance and the profile of drilled holes were investigated experimentally. Test parameters including discharge current, dielectric spray pressure and electrode tool rotational speed were taken and then the machining rate (MR), electrode wear rate (EWR), average over-cut (AOC) and taper angle (TA) were measured in order to assess the drillability of EDM. After experimental study, an analysis of variance was performed to identify the effect of the importance of test parameters on experiment outputs. In the second phase of this study, optimum process parameters were determined using signal-to-noise analysis and response surface methodology (RSM) for mono-optimization and multi-response optimization, respectively. In the last phase, regression analysis and artificial neural network (ANN) models for predicting the MRR, EWR, AOC and TA. As a result of experimental analysis, discharge current was the most important parameter for micro-drilling with EDM. It was found out that this parameter influenced positively MR, while it has negatively an effect on EWR, AOC and TA. Mathematical model based on ANNs exhibited a successful performance for predication of outputs. Optimum process parameters which were discharge current of 10.18 Å, dielectric liquid pressure of 58.78 bar and electrode tool rotational speed of 100 rpm for multi-objective optimization were determined through RSM with desirability function analysis in micro-deep hole EDM drilling of AISI 304 stainless steel.
Similar content being viewed by others
References
Meral G, Sarıkaya M, Dilipak H, Şeker U (2015) Multi-response optimization of cutting parameters for hole quality in drilling of AISI 1050 steel. Arab J Sci Eng 40(12):3709–3722
Chow HM, Lee SM, Yang LD (2008) Machining characteristic study of friction drilling on AISI 304 stainless steel. J Mater Process Technol 207(1):180–186
Kuram E, Ozcelik B (2013) Multi-objective optimization using Taguchi based grey relational analysis for micro-milling of Al 7075 material with ball nose end mill. Measurement 46(6):1849–1864
Yılmaz V, Sarıkaya M, Dilipak H (2015) Deep micro-hole drilling for Hadfield steel by electro-discharge machining (EDM). Mater Technol 49(3):377–386
Kuppan P, Rajadurai A, Narayanan S (2008) Influence of EDM process parameters in deep hole drilling of Inconel 718. Int J Adv Manuf Technol 38(1–2):74–84
Ay M, Çaydaş U, Hasçalık A (2013) Optimization of micro-EDM drilling of Inconel 718 superalloy. Int J Adv Manuf Technol 66(5–8):1015–1023
Asokan T, Reddy SS, Costa PDE (2000) Electrical discharge drilling of titanium alloys for aerospace applications. In: Proceedings of 19th AIMTDR conference. IIT Madras, Chennai, pp 161–165
Mohan B, Rajadurai A, Satyanarayana KG (2002) Effect of SiC and rotation of electrode on electric discharge machining of Al–SiC composite. J Mater Process Technol 124:297–304
Mohan B, Rajadurai A, Satyanarayana KG (2004) Electric discharge machining of Al–SiC metal matrix composites using rotary tube electrode. J Mater Process Technol 153–154:978–985
Puertas I, Luis CJ, Alvarez L (2004) Analysis of the influence of EDM parameters on surface quality, MRR and EW of WC–Co. J Mater Process Technol 153:1026–1032
Lee CS, Heo EY, Kim JM, Choi IH, Kim DW (2015) Electrode wear estimation model for EDM drilling. Robot Comput-Integr Manuf 36:70–75
Plaza S, Sanchez JA, Perez E, Gil R, Izquierdo B, Ortega N, Pombo I (2014) Experimental study on micro EDM-drilling of Ti–6Al–4V using helical electrode. Precis Eng 38(4):821–827
Jahan MP, San Wong Y, Rahman M (2010) A comparative experimental investigation of deep-hole micro-EDM drilling capability for cemented carbide (WC–Co) against austenitic stainless steel (SUS 304). Int J Adv Manuf Technol 46(9–12):1145–1160
Pradhan BB, Masanta M, Sarkar BR, Bhattacharyya B (2009) Investigation of electro-discharge micro-machining of titanium super alloy. Int J Adv Manuf Technol 41(11–12):1094–1106
Wang D, Zhao WS, Gu L, Kang XM (2011) A study on micro-hole machining of polycrystalline diamond by micro-electrical discharge machining. J Mater Process Technol 211(1):3–11
Sarıkaya M, Yılmaz V, Dilipak H (2016) Modeling and multi-response optimization of milling characteristics based on Taguchi and gray relational analysis. Proc Inst Mech Eng Part B J Eng Manuf 230(6):1049–1065
Sarıkaya M, Güllü A (2014) Taguchi design and response surface methodology based analysis of machining parameters in CNC turning under MQL. J Clean Prod 65:604–616
Davoodi B, Eskandari B (2015) Tool wear mechanisms and multi-response optimization of tool life and volume of material removed in turning of N-155 iron–nickel-base superalloy using RSM. Measurement 68:286–294
Joardar H, Das NS, Sutradhar G, Singh S (2014) Application of response surface methodology for determining cutting force model in turning of LM6/SiC P metal matrix composite. Measurement 47:452–464
Moghaddam TB, Soltani M, Karim MR, Baaj H (2015) Optimization of asphalt and modifier contents for polyethylene terephthalate modified asphalt mixtures using response surface methodology. Measurement 74:159–169
Mukherjee I, Ray PK (2006) A review of optimization techniques in metal cutting processes. Comput Ind Eng 50(1):15–34
Pham DT, Dimov SS, Bigot S, Ivanov A, Popov K (2004) Micro-EDM-recent developments and research issues. J Mater Process Technol 149(1):50–57
Yan BH, Wang CC (1999) The machining characteristics of Al2O3/6061Al composite using rotary electro-discharge machining with a tube electrode. J Mater Process Technol 95:107–111
Chen SL, Yan BH, Huang FY (1999) Influence of kerosene and distilled water as dielectrics on the electric discharge machining characteristics of Ti–6Al–4V. J Mater Process Technol 87:107–111
Ho KH, Newman ST (2003) State of the art electrical discharge machining (EDM). Int J Mach Tools Manuf 43:1287–1300
Ferraris E, Castiglioni V, Ceyssens F, Annoni M, Lauwers B, Reynaerts D (2013) EDM drilling of ultra-high aspect ratio micro holes with insulated tools. CIRP Ann Manuf Technol 62(1):191–194
Kıvak T, Samtaş G, Çiçek A (2012) Taguchi method based optimisation of drilling parameters in drilling of AISI 316 steel with PVD monolayer and multilayer coated HSS drills. Measurement 45(6):1547–1557
Sarıkaya M, Güllü A (2015) Multi-response optimization of MQL parameters using Taguchi based GRA in turning of difficult-to-cut alloy Haynes 25. J Clean Prod 91:347–357
Korkut I, Acır A, Boy M (2011) Application of regression and artificial neural network analysis in modelling of tool–chip interface temperature in machining. Expert Syst Appl 38(9):11651–11656
Karabulut Ş (2015) Optimization of surface roughness and cutting force during AA7039/Al2O3 metal matrix composites milling using neural networks and Taguchi method. Measurement 66:139–149
Karabulut Ş, Karakoç H (2015) Investigation of surface roughness in the milling of Al7075 and open-cell SiC foam composite and optimization of machining parameters. Neural Comput Appl. doi:10.1007/s00521-015-2058-x
Mia M, Dhar NR (2016) Response surface and neural network based predictive models of cutting temperature in hard turning. J Adv Res 7(6):1035–1044
Mia M, Khan MA, Dhar NR (2016) Performance prediction of high-pressure coolant assisted turning of Ti–6Al–4V. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9468-5
Mia M, Dhar NR (2016) Prediction of surface roughness in hard turning under high pressure coolant using artificial neural network. Measurement 92:464–474
Cetin MH, Ozcelik B, Kuram E, Demirbas E (2011) Evaluation of vegetable based cutting fluids with extreme pressure and cutting parameters in turning of AISI 304L by Taguchi method. J Clean Prod 19:2049–2056
Mia M, Khan MA, Rahman SS, Dhar NR (2016) Mono-objective and multi-objective optimization of performance parameters in high pressure coolant assisted turning of Ti–6Al–4V. Int J Adv Manuf Technol. doi:10.1007/s00170-016-9372-z
Ezilarasan C, Kumar VSS, Velayudham A (2013) An experimental analysis and measurement of process performances in machining of Nimonic C-263 super alloy. Measurement 46(1):185–199
Sarikaya M (2015) Optimization of the surface roughness by applying the Taguchi technique for the turning of stainless steel under cooling conditions. Mater Tehnol 49(6):941–948
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Rights and permissions
About this article
Cite this article
Sarıkaya, M., Yılmaz, V. Optimization and predictive modeling using S/N, RSM, RA and ANNs for micro-electrical discharge drilling of AISI 304 stainless steel. Neural Comput & Applic 30, 1503–1517 (2018). https://doi.org/10.1007/s00521-016-2775-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00521-016-2775-9