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Parametric optimization of wire EDM process for single crystal pure tungsten using Taguchi-Grey relational analysis

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Abstract

Magneto-caloric materials such as Beryllium, Gallium, Cadmium and Tungsten are most suitable for regulating the heat flow at a cryogenic temperature below 10 K. Among these, Tungsten is preferable as a switching element in magnetoresistive heat switches because of its high Debye temperature and low critical superconducting temperature. Machining tungsten is difficult because of its inherent properties. Due to this, WIRE Electrical Discharge Machining (WEDM) process is preferable to convert tungsten into the desired shape and size. Thus, current research has focused on the WEDM process. Before machining of material, parametric optimization is needed to reduce the operating cost, material wastage, number of experiments and time. Therefore, the present research has focused on optimizing the process parameters using the Taguchi Grey Analysis (TGA) method for the WEDM process of tungsten. In this method, seven input parameters such as pulse on, pulse off time, arc off time, water pressure, wire feed, wire tension, gap voltage, and three output parameters, such as material removal rate (MRR), Kerf width and surface roughness value, are chosen for parametric optimization. The parametric optimization study of machining single-crystal pure tungsten using WEDM signifies that the response parameters should (MRR is 0.298 mm3/min, Kerf width is 0.346 mm, Surface roughness is 1.834 μm).

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Acknowledgement

This work is carried out as a part of the ongoing technology development project entitled “Design and Development of Magneto Resistive Heat Switch”. This project is supported by the SAC, Ahmedabad, ISRO, Government of India, Project Number No. YS/PD-IP/2021/364.

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Authors and Affiliations

  1. Sustainable Thermal Energy Systems Laboratory (STESL), Department of Mechanical Engineering, National Institute of Technology Rourkela, Rourkela, Odisha, 769008, India

    Pritam Choudhary, Yash Bhausaheb Desale, Gautam Ranjan & B Kiran Naik

  2. Thermal Engineering Division, Space Applications Centre, ISRO, Ahmedabad, 380015, India

    Vivek Kumar Singh

Authors
  1. Pritam Choudhary
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  2. Yash Bhausaheb Desale
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  3. Gautam Ranjan
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  4. B Kiran Naik
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  5. Vivek Kumar Singh
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Corresponding author

Correspondence to B Kiran Naik.

Appendices

Abbreviations

ANOVA:

Analysis of variance

BPNN:

Back-propagation neural network

DF:

Degree of freedom

EDM:

Electro-discharge machining

GRG:

Grey relation grade

MRR:

Material removal rate

MS:

Mean square

RSM:

Response surface methodology

SAA:

Simulated annealing algorithm

SS:

Sum square

TGA:

Taguchi grey analysis

Alphabets

A:

Pulse on time

B:

Pulse of time

C:

Arc off time

D:

Gap voltage

E:

Wire feed rate

F:

Wire tension

G:

Water pressure

Ra:

Surface roughness

Greek symbols

ψ:

Distinguishing coefficient

∆:

Difference

γ:

Grey relational coefficient

ξ:

Grey relational grade

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Choudhary, P., Desale, Y.B., Ranjan, G. et al. Parametric optimization of wire EDM process for single crystal pure tungsten using Taguchi-Grey relational analysis. Sādhanā 48, 152 (2023). https://doi.org/10.1007/s12046-023-02189-x

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  • DOI: https://doi.org/10.1007/s12046-023-02189-x

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