Title: Performance analysis of µED-milling process using various statistical techniques

Authors: G. Karthikeyan; J. Ramkumar; Shalabh; S. Aravindan

Addresses: Department of Mechanical Engineering, Indian Institute of Technology, Kanpur 208016, UP, India. ' Department of Mechanical Engineering, Indian Institute of Technology, Kanpur 208016, UP, India. ' Department of Mathematics and Statistics, Indian Institute of Technology, Kanpur 208016, UP, India. ' Department of Mechanical Engineering, Indian Institute of Technology, Delhi 110016, India.

Abstract: µED-milling is a newly evolved process for machining complex 3D profiles in various micro devices. To achieve desired machining performance of the process, it is necessary to understand the influence of parameters on responses such as MRR and TWR. The parameters which are expected to control the process are tool rotational speed, feed rate and aspect ratio along with the fundamental parameter as energy. This work presents the use of various statistical tools on experimental data to study single and multiple objective performance characteristics of the process. Initially, an empirical equation for MRR and TWR are generated by multiple regression analysis with a confidence interval of 95 and 99% for each coefficient to generalise the models. To study the influence of individual parameter on single performance characteristics, tools such as S/N ratio and ANOVA are employed. Further using grey relational algorithm (GRA) technique, the multi performance characteristic of maximising MRR and minimising TWR is solved. The result shows that for single performance study parameters energy and speed are superior whereas for multi performance analysis feed contributes significantly.

Keywords: regression; electrical discharge machining; electro-discharge machining; micro EDM; electrical discharge milling; micromachining; micromilling; material removal rate; MRR; tool wear rate; TWR; process parameters; S/N ratio; analysis of variance; ANOVA; grey relational algorithm; GRA; 3D profiles; profile machining; tool rotational speed; feed rate; aspect ratio; energy.

DOI: 10.1504/IJMMM.2012.045984

International Journal of Machining and Machinability of Materials, 2012 Vol.11 No.2, pp.183 - 203

Received: 09 Aug 2010
Accepted: 05 Jan 2011
Published online: 23 Aug 2014 *

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