Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

WEDM Process Parameter Optimization of FSPed

Copper-BN Composites

Titus Thankachan, K. Soorya Prakash & M. Loganathan

To cite this article: Titus Thankachan, K. Soorya Prakash & M. Loganathan (2017): WEDM
Process Parameter Optimization of FSPed Copper-BN Composites, Materials and Manufacturing
Processes, DOI: 10.1080/10426914.2017.1339311

To link to this article: http://dx.doi.org/10.1080/10426914.2017.1339311

Accepted author version posted online: 13

Jun 2017.

Submit your article to this journal

View related articles

View Crossmark data

Full Terms & Conditions of access and use can be found at

http://www.tandfonline.com/action/journalInformation?journalCode=lmmp20

Download by: [University of Florida] Date: 13 June 2017, At: 16:22

 WEDM Process Parameter Optimization of FSPed Copper-BN Composites

Titus Thankachan1 , K. Soorya Prakash2, M. Loganathan3

1
Research Scholar, Department of Mechanical Engineering, Anna University Regional
Campus, Coimbatore , Tamil Nadu, INDIA, 2Assistant Professor, Department of
Mechanical Engineering, Anna University Regional Campus, Coimbatore, Tamil Nadu,
INDIA, 3LGB Balakrishnan and Bros Ltd, Annur, Coimbatore, Tamil Nadu, INDIA.

Corresponding Author Titus Thankachan, E- mail: titusmech007@gmail.com

Abstract

A systematic view on evaluating the machining characteristics of Wire Cut Electrical

Discharge Machining (WEDM) employing Taguchi Method and Grey Relational

Analysis based multi objective optimization is provided in this research article. The

outcome of various WEDM processing parameters including pulse discharge on time

(PulseON), pulse discharge off time (PulseOFF), wire feed rate (WireFR) along with the

material characteristics of varying Boron Nitride (BN) volume fractions while machining

a friction stir processed (FSPed) copper-BN surface composite was investigated. The

output responses considered in this research includes Material Removal Rate (MRR) and

Surface roughness (Ra) which was obtained from the L27 orthogonal array based on the

above said input factors. ANOVA was performed and PulseON and BN volume fraction

was found most significant for MRR, while PulseON, PulseOFF influences the most in

attaining minimal Ra values. Based on the obtained experimental values for MRR and Ra,

a mathematical model was developed based on the control factors and was proved to be

precise in predicting the output response. An optimal combination of input control factors

1
was finalized through grey relational analysis and the same proved to achieve the utmost

MRR (20.19 mm3/min) and nominal Ra (3.01 µs) values.

KEYWORDS: Wire; edm; surface; composites; taguchi; machinability; roughness.

Received 12 Dec 2016, Accepted 23 May 2017

INTRODUCTION

Composite materials can be identified as the combination of two or more sorts of

materials which exhibit an enhanced performance when developed as a single material

[1]. Reinforcing ceramic particles into a matrix material enhances a wide range of

properties, while these incorporations into a base metal can lead to reduction of major

bulk properties including thermal and electrical properties. Sustaining thermal and

electrical properties of certain metal like copper while increasing its mechanical aspects

through reinforcement dispersion was considered a tiresome work which paved way for

the development of surface composite. Even though methods like electron beam, laser

melting and plasma spray methodology exists in developing surface composites, the

formation of avoidable phases due to high temperature has been a major drawback. As a

replacement, Friction Stir Processing (FSP) which works under the principle of Friction

Stir Welding (FSW) was developed wherein the surface of the material is brought to a

semi-solid condition and the reinforcement is mixed within the matrix material using a

FSP tool through stirring. These type of copper-based surface composite can be opted for

applications such as electrical sliding contacts, heat exchangers etc., but a minimal

number of researches has only been carried out in this area [2,3]. An effective dispersion

2
of BN particles onto copper surface was carried out by Titus Thankachan et al., and the

results found promising with increased strength, hardness, wear resistance and corrosion

resistance. It was also put forward by the same researchers that the presence of boron

element can absorb radioactive raditions and henceforth the successful dispersion of BN

onto copper surface can enable the developed material as a main candidate for radioactive

waste disposal carrier [4].

Apart from considering the enhanced properties of a developed copper surface composite

material, machinability of the same also has to be focussed as the introduction of hard

ceramic materials along with FSP processing changes the morphology of the material

entirely. Machining of materials employing conventional processing seems to be a

difficult process as per literatures [5] and in the case of surface composites as the layer

happens for a certain depth, usage of conventional machining might leave a chance to

deteriorate the enhanced property because of temperature and vibration created during the

operation. To this account, it can also be stated that residual stress created during the

conventional machining process also can affect the performance of the material as these

advanced surface composites might be used for complex and precise applications. A

detailed survey over literatures on non-conventional machining processes proved that

Wire Cut Electrical Discharge Machining (WEDM) can be efficiently used in machining

these hard materials at minimal tolerance which is indispensable for precision

applications including tool-die industries, manufacturing firms etc. WEDM process

removes material from workpiece as a combination of thermal and electrical process

3
comprising of a computer controlled wire electrode which discharges thousands of

electric sparks per second leading to the formation of craters at a certain depth [6-8].

The outcome of the machining for example surface roughness (Ra) of the workpiece,

Material Removal Rate (MRR) through WEDM is managed by its processing parameters

and their interactions inclusive of pulse discharge on time (PulseON), pulse discharge off

time (PulseOFF), wire feed rate (WireFR), peak current, servo voltage etc [9]. The setting

of machining parameters in WEDM machine is a traditional method followed in tool and

die industries as most of the workpieces involves iron and steel materials. For these

materials along with certain commonly used materials, well-defined values for the

process parameters provided by the WEDM machine suppliers will be available and

machinist’s expertise along with these values will be more enough in machining. While

considering newer surface composites, the ceramic particles dispersed into copper matrix

might include insulating characteristics and the defined values provided by the machine

supplier will get nullified in such conditions. Hence to attain the required output response

for these type of advanced materials, apart from trial and error experimentation an

effective optimal process parameters along with its interactional effects that govern the

response has to be defined.

Numerous researches have been carried out in the field of WEDM to attain the maximum

performance of the WEDM process which includes MRR, Ra, cutting accuracy etc., but

the stochastic nature of operation along with its numerous number of machining control

factors limits the solution for the above said crisis. Numerous studies has been reported in

machining composite material through WEDM so as to find out optimal combinations of

4
process control factors to achieve the best and efficient output response[10-13]. Nil

number of studies has been reported till this period of time in the case of surface

composites, which has made this work more necessary. In order to machine the copper-

based surface composite employing WEDM, a new set of optimal combinations of the

control factors has to be finalized so as to attain a higher MRR value with minimal Ra

value. A detailed survey of literatures for optimizing WEDM parameters of various

materials [14-18] has been carried out so as to confirm the control factors and its

operating range; most of the studies implies that peak current, PulseON, PulseOFF, and

WireFR, has major significance in availing higher MRR and minimal Ra values.

Taguchi’s method can be seen effectively used in numerous researches in which each

performace characteristics will be analysed separately and the optimal conditions for the

same will be investigated. It has been proved by researchers that a single combination of

the process parameters would not be able to satisfy or attain the best output response in

case of WEDM and hence forth to attain the best output that satisfies all the output

responses the researchers judgement comes into focus which may be uncertain. In this

scenario multi-response optimization techniques comes into handy but however for

WEDM process parameters based investigations it was found to be minimal that too with

repetitive set of response parameters. Even though certain studies focused on optimizing

the WEDM process parameters to attain the best maximum material removal rate with

better surface integrity through principal component analysis techniques [19], utility

concept methodology [20] etc, the effective usage of Grey Relational Analysis (GRA)

techinque along with taguchi method is seen minimal.

5
As addressed above even though various studies regarding the investigation of optimal

combinations for MRR and Ra values has been carried out in the field of iron, nickel,

titanium alloys etc along with certain composites of aluminum and magnesium; WEDM

machinability study over the copper-based surface composites was found nil. In this

context, a research to evaluate the WEDM machinability and thereby obtain an optimal

combination of process parameters from a set of varying PulseON, PulseOFF, and WireFR

values along with the varying volume fractions of reinforcement is carried out in this

research so as to attain maximum MRR and minimal Ra values.

MATERIALS AND METHODS

Substrate considered in this study to develop surface composites was commercially

available pure copper (99.98% copper) termed as electrolytic copper and was acquired

with a dimension of 150 mm length, 50 mm breadth and 6 mm height respectively. Boron

Nitride (BN) particles of an average size of 1 µm were attained from Sigma-Aldrich and

the confirmation of the same was carried out through XRD. BN known as solid self-

lubricating material is an advanced ceramic particle encompossing the ability to enhance

wear resistant properties is used as reinforcement in surface composite applications such

as sliding contacts. In this study, BN has been dispersed into the surface of copper matrix

for a depth of 6 mm and for varying volume fractions (5, 10 and 15 vol.%) as it is

considered to be one of the major controlling factors in machining. Default brass wire of

0.25 mm diameter was considered as the wire for the machining procedure.

6
Working of friction stir processing methodology to develop a surface composite in

stepwise is as shown in figure 1 (a-e). A groove of varying width based on the dispersion

amount of particles was cut using WEDM into which BN particles were filled and

compacted. In order to avoid the scattering away of particles from groove during FSP

process, a double tempered H13 steel tool without pin was allowed to pass above the

groove at a rotational and traverse speed of 1000 rpm and 30 mm/min respectively. Then

an FSP tool of shoulder diameter 20 mm, pin diameter 6 mm and pin length 5 mm was

passed through the groove which makes the material into a semisolid condition due to the

temperature created and pin stirs the particles into the copper matrix dispersing the

particles throughout the developed surface composites. The FSP tool was rotated at an

optimized rotational speed of 1000 r.p.m and passed above the copper material at a

traverse speed of 30 mm/min utilizing a CNC milling machine with displacement

controlling facility. Plunge condition of tool during compacting and stirring phase was

ensured uniform for all the developed set of composites by controlling the vertical

displacement of the employed CNC milling machine.

Scanning Electron Micrographs (SEM) for the developed copper surface composites

dispersed with 5 and 15 volume fractions of BN as shown in figure 2 demonstrates that

the particles have been dispersed throughout the surface and a good bonding exists

between the particles and matrix material. Average Vickers hardness obtained from FSP

zone states that hardness of the surface composites tends to increase. Similarly, the

breaking down of grain particles due to stirring action of FSP tool at high temperature

7
tends to increase the density of developed surface composites with respect to BN particle

incorporation. The hardness and density values are presented in table 1.

Copper based surface composites reinforced with varying volume fractions of BN

developed in this study has an approximate friction stir surface width of 20 mm and

surface composite thickness of 6 mm. So the rest of the copper pieces has to be cut off

and the FSP zone in which the particles has been dispersed along should be machined so

as to study the exact MRR and Ra. The specimen cut accordingly has been demonstrated

in figure 3 as the specimen cutting procedure. Machining of the developed copper-based

surface composites was carried out by a CNC WEDM machine of make Agie Charmilles

CUT 20P. Volume fractions of BN which governs the property of the developed surface

composite to a great extent is considered as one of the major control factor in this

research and further more, based on a detailed survey of literatures, machine manuals and

through preliminery experiments it was concluded that PulseON, PulseOFF, and WireFR

administer a great degree to attain better Ra and MRR [21]. WEDM based researches in

machining generally considered these three parameters as design factors and has attained

better results which prompted as a major reason for factor selection. The levels of control

factors were optimized to a smaller range as per the views from literatures and are as

shown in table 2 based on which the Taguchi’s experimental design was acquired.

Response factors considered in this study to evaluate the machining performance include

MRR and Ra, as these two aspects are the major considerations. Ra of the machined

surface composites was evaluated employing SJ 201P model surface tester of made

Mitutoyo, while MRR was estimated using the below given equation (1).

8
 W
MRR (1)
t

where ‘W’ stands for the weight loss happened during the machining process,’ ρ’ for

density and ‘t’ for the time taken per cut respectively.

In order to study the effect of each factor considering even the slightest changes, a

specially build experimental design is most essential. In such cases significance of

Design of Experiments (DoE) developed by Taguchi is inevitable. Based on literature

surveys, preliminary testing and based on experts review, PulseON, PulseOFF, WireFR were

selected as the major machining parameter along with material parameter. Each of the

governing factors was varied accordingly to an arithmetic mode as shown in table 2.

Minitab software of version 16 was employed in this study to develop an experimental

design based on the 4 input control factors with levels 3 each and an orthogonal array

L27 was selected as clearly pointed out in table 3. It is a known fact that despite the

above said three machine parameters, certain other operating factors has to be considered

while undergoing WEDM machining processes and these variables were kept constant

after optimizing through trial experiments. A brief detail on the various processing

parameters of WEDM machine considered in this study for machining copper-based

surface composite with varying BN volume fractions is provided in table 4.

In this investigation, Taguchi’s technique was exploited to optimize the control factors in

order to achieve better Ra and high MRR value. For this two tools was efficiently used (i)

an orthogonal array which develops a design matrix of varying trial combination so as to

model and study the influence of each control factors on the response parameters; in this

9
study an L27 OA. (ii) Analysis of Variance (ANOVA) method to confirm the results,

establish the sum of square values, F values and thereby study the significance and

contribution of each parameter on the response characteristics [22]. Response values

obtained for the OA trials are changed accordingly to its signal-to-noise ratio (SN ratio)

using ANOVA. Based on the results to be attained SN ratio values can be classified

mainly into three viz. higher the better, nominal the better and smaller the better where

higher the better and smaller the better are considered in this study for MRR and Ra

respectively. Equations used to calculate the SN ratio values for higher the better (HB)

and smaller the better (SB) are provided below as equation 2 and 3 correspondingly.

1 r
(S/ N)HB 10log10 j 1
(1/ y 2j ) (2)
r

1 r
(S/ N)HB 10log10 j 1
y2j (3)
r

where ‘y’ represents the response value at a trial number of ‘j’, and ‘r’ denotes the total

number of trials. The maximum value of the SN ratio is considered as the best process

parameter and based on this the optimum process characteristics combination to attain the

best values for each response parameter is chosen.

Multi-response optimization of certain process parameters through GRA technique is

mainly used to establish an interrelation between the output responses and thereby obtain

an optimal combination of parameters which will increase the productivity with enhanced

product quality. In this study GRA methodology is utilized to attain better MRR with

superior Ra value and the incorporation of Taguchi method with GRA in this study has

made it an excellent statistical tool to solve this multi objective problem where the output

10
responses are converted into a single response and the optimal combination of control

factors are thus obtained to acquire better MRR with superior Ra value. The steps

involved in GRA methodology are as given below.

Step I: Obtaining the SN ratio values for the output responses (MRR, Ra) based on

equation 2 and 3 respectively, with criteria higher the better and smaller the better for

MRR and Ra respectively.

Step II: Preprocessing of the available SN ratio value through normalizing the values

between 0 to 1 so as to avoid the variability and thereby distribute the data evenly in an

acceptable range. Formulae used for preprocessing of MRR is based on the criteria higher

the better and smaller the better for Ra respectively

Preprocessing formulae for higher the better criteria

max a i (k) a i (k)

x*i (k) (4)
max a i (k) min a i (k)

Preprocessing formulae for smaller the better criteria

a i (k) min a i (k)

x*i (k) (5)
max a i (k) min a i (k)

where the terminology x*i(k) stands for normalized values for the obtained output

response ai(k), in which i and k represents the experimental number and comparability

sequence respectively. Max ai(k) and min ai(k) stands for the maximum and minimal

values within the output responses ai(k).

11
Step III: Calculating the deviation sequence (Δoi(k)) from the reference sequence (x*o(k))

which is considered as 1 and the comparability sequence (x*i(k)) as given in equation 6.

oi (k) | x*o (k) x *i (k) | (6)

Step IV: Calculating the Grey Relational Coefficient (GRC) value based on the deviation

sequence (Δoi(k)) value obtained, identification coefficient (ζ) value normally taken as 0.5

and the maximum (Δmax) and minimum (Δmin) value of obtained deviation sequence

respectively employing equation 7.

min max
i k (7)
oi k max

Step V: Computing the Grey Relational Grade (GRG) which can be obtained through

averaging the corresponding GRC values for each output response and this step converts

the multiple objective response to a single objective; the formulae to obtain GRG is as

shown below in equation 8.

n
1
i i k (8)
n k 1

where γi stands for GRG for ith trial and n is the number of trials.

RESULTS AND DISCUSSION

SN ratio response graph obtained from L27 OA responses as exposed in figure 4

demonstrates the effect of each processing parameters on the MRR values. It is clear

from figure that with increase in the volumetric fraction of BN values, the MRR tends to

decrease. It can be observed from SEM micrographs of the developed surface composite

as shown in figure 2 that with an increase in the volume fraction of BN more particles

12
gets dispersed uniformly into the copper matrix. This increment of BN particles into

copper matrix increases the hardness to a great extent which thereby reduces the WireFR

and hence the MRR value. Another prospect of MRR value reduction with increment in

volume fraction of BN particles can be stated as BN being a good insulator to electricity

protrudes out in the matrix during cutting which reduces the electric spark responsible for

the machining operation and thereby decreases the MRR values.

PulseON can be considered as one of the main parameters that influence MRR

values and the SN ratio graph as shown in figure 4 displays that with an increase in

PulseON time, MRR value tends to decrease. WEDM machining being a discontinuous

spark generated based machining process, increment in PulseON time increases the

intensity of spark generated. At high PulseON time (in this study B3), high-intensity

discharge pulses will be created leading to the formation of deeper cuts also called as

craters on the composite material thereby increasing MRR [23] and henceforth results in

deeper crater formation in next spark [24].

Pulse interval, PulseOFF in this study affects machining to a great level as with a reduction

in PulseOFF time the machining operations gets faster thereby increasing MRR. The same

can be stated through this research based on Taguchi method based analysis of MRR

value obtained through L27 OA. From figure 4, it can be noted that MRR value has a

slight reduction between levels C1 and C2 and then exhibits a drastic reduction between

C2 and C3 which can be accounted to the reason that even though at C1 level higher

MRR value has been obtained, the debris of the workpiece was not properly flushed away

13
along with de-ionized water and thereby leading to improper spark [25] during the next

PulseON time and it can be further stated that reduction of PulseOFF time below level

C1would have resulted in reduction of MRR value.

Unlike other 3 parameters, WireFR with its increment exhibited a different behavior over

MRR values in this research. It can be observed from figure 4 that MRR gets increased

from level D1 to D2 and gets decreased with further increment in WireFR. WEDM is a

thermal erosion based processes were both workpiece and electrode gets eroded away. So

reduced WireFR may lead to the state of eroding away of wire electrode thereby reducing

spark energy created and henceforth decreasing the MRR value. With increment in

WireFR, proper spark energy will be provided along the circumference of the wire

electrode increasing the MRR value. The reduction of MRR with a further increment of

WireFR can be explained as the effect of improper spark generated during the machining

process. It can be further clarified that elevated WireFR reduces the heat developed

throughout the machining zone and thereby reduces the MRR [26].

From Table 5, the statistical analysis of varying process parameters along with its

influence over the MRR can be studied. It is a known fact that the significance of a

parameter can be evaluated through ANOVA when its ‘P’ value stands below 0.05 and it

can be notified from table 5 that every processing parameter in this study holds a

significant effect on the MRR value. Among four processing parameters based on

ANOVA table, it can be stated that control factor PulseON is the most significant

parameter with a contribution percentage of 38.65% followed by Volume Fraction

14
(26.2%), PulseOFF (25.03%) and WireFR (8.78%). It can also be affirmed based on results

that all the four processing parameters considered in this research influences the MRR

values and controlling these values helps in attaining better process parameters.

SN ratio values of the Ra experimental values obtained through Taguchi method

implying smaller the better mode for L27 OA is as shown in table 3. Considering the SN

ratio value, the influence of each processing parameter on the Ra values are evaluated

using Taguchi method and ANOVA. SN ratio response graph for Ra values are provided

in figure 5 which states that Ra values increase with respect to volume fraction, PulseON,

and WireFR while increment in PulseOFF time reduces the Ra value.

Figure 5 demonstrates that with an increase in BN particles, Ra value tends to

increase despite BN particles being a self-lubricating material which can enhance the

machinability of the developed copper surface composites. This increment in Ra values

may be attributed to the reason that BN particles, considered to be a good insulator of

electricity acts as a hitch in generating electrical sparks once it protrudes out and thereby

reducing the surface integrity. With increment in the volume fraction of BN particles

being dispersed in an effective manner throughout the copper surface composites; BN

particles interrupts the smooth machining through WEDM process. Another facet that can

be attributed for the increment in Ra value is the electric spark that develops a thermal

field which creates HAZ and thus some part of the material gets melted away. The melted

away workpiece, in this case, copper, gets carried away with the dielectric fluid

protruding the BN particles outside thereby affecting the surface integrity of the

15
developed copper surface composites.

SN ratio response graph for Ra from figure 5 reveals that with respect to increase in

PulseON value, Ra values tend to increase. It states that in order to achieve a better surface

finish, the PulseON value has to be set at minimal. The increment in PulseON generates

electric sparks with elevated discharge energy which creates deepen and widen craters

leading to localized erosion. This increment in PulseON increases the thermal field created

leading to melting away of copper matrix material fully and partially protruding BN

particles and thereby increasing Ra. The presence of melt expulsions due to electric spark

for long duration can also be accounted as a reason for the increase in Ra [27].

Influence of PulseOFF time on minimization of Ra value based on SN ratio analysis for

experimental results is as shown in figure 5 and the same states for an increase in interval

between each spark discharge reduces Ra values. WEDM process involves melting down

of workpiece and increment in PulseOFF time allows de-ionized water to pass through the

spark gap thereby flushing away the debris so as to attain a clean surface during next

spark discharge interval. This dielectric fluid course through the spark gap assists in

debris removal and at the same time avoids solidification of matrix material partially

melted at HAZ and thereby provides a clean surface for next spark discharge. This

happening that occurs at higher PulseOFF time attributes for fine surface finish for a

material during WEDM.

WireFR, one of the considered control factor in this research for minimizing Ra values has

the least influence on governing the Ra of the developed surface composite. It can be seen

16
from figure 5 that with increment in levels of WireFR, Ra value tends to increase and for

further increment Ra value decreases. This behavior of Ra with respect to WireFR can be

attributed to the improper electric spark created with respect to increment in WireFR.

ANOVA analysis of the four processing parameter over Ra was carried out to identify

and categorize based on significance and the evaluation results obtained were as shown in

table 6. It can be visualized from the table that PulseON duration (48.1% contribution) has

the maximum influence over Ra value followed by PulseOFF time (31.07% contribution).

It can be understood that volume fraction of BN particles also influence Ra value to a

great level while WireFR had a minimal effect on the considered response which

contributes about 7.37% of the total contribution.

The normalized values of the SN ratio for MRR and Ra values based on the criteria

higher the better and smaller the better according to equations 4 and 5 are shown in table

7 along with GRC values for MRR and Ra, GRG and rank. The GRG values are

calculated by averaging GRC values of MRR and Ra, considering equal weight for both

MRR and Ra. Ranking of GRG value is carried out by considering the higher GRG value

as rank 1 and so on. The control factor combination rated rank 1 in GRG value is

considered as the optimal combination that achieve the better values for MRR and Ra in

the L27 OA. From table 8 it can be stated that trial number 7 (volume fraction (5%),

PulseON (130μs), PulseOFF (40μs), and WireFR (7m/ms)) exhibits the maximum MRR value

with minimal Ra value.

17
In GRA technique, a relational degree among the control factors concerning the output

response is evaluated based on the GRG values. Table 8 shows the response table which

depicts the average value of GRG for each level of the control factors so as to finalize the

optimal factors. It is a known fact that the optimal parameter level is concluded based on

the maximum mean value of GRG. From table 8 it can be seen that the maximum mean

value of GRG (represented bolded and starred) is exhibited by level 1 for volume fraction

of BN and PulseOFF, level 3 of PulseON and level 2 of WireFR. From the response table it

can be seen that PulseON affects WEDM to attain better performance characteristics

followed by PulseOFF, WireFR and BN volume fractions.

As a part of this research, a linear mathematical model was derived based on the control

factors to attain the responses. Multiple Linear Regression (MLR) models were derived

for MRR and Ra based on volume fraction (A), PulseON (B), PulseOFF (C), and WireFR

(D).The basic expression for a general MLR model is as expressed in equation 4. The

same MLR model can be used to study the effect of individual control factor over the

output response.

Y X0 X1 A X2 B X3 C X4 D (9)

where X0, X1, X2, X3, X4 stands for constants, Y for response variables and A, B, C, D

stands for the control factors.

Based on the L27 OA an MLR model for MRR values was developed and is expressed as

equation 5. From the model, it can be seen that the variables A and C has a negative

impact on the MRR values while B and C showcased an additive influence. The

18
developed MLR model based on the L27 OA in this study exhibited an R-Sq value of

90.50% and R-Sq (adj) value of 88.77% which describes the deviations between the

experimental predicted values. It was confirmed that the developed MLR model

efficiently modeled the MLR value and is shown in figure 6.

MRR 31.4794 0.421333 A 0.499667 B 0.400222 C 0.805556 D

(10)

Ra 0.93963 0.0121111 A 0.0194444 B 0.0158889 C 0.0222222 D

(11)

Similarly, a model to relate the control factors with Ra was developed based on the

experimental results obtained from the L27 OA trials and is expressed as equation 6. The

developed MLR model confirmed its efficiency to predict the Ra values effectively with

R-Sq and R-Sq (adj) values of 87.08% and 84.73% respectively. It can be noticed from

equation 6 that all the three factors other than ‘C’ have a negative impact in reducing the

Ra values. The effective results of the MLR model with experimental Ra values are shown

in figure 7.

The optimal combinations to attain the maximum MRR values and minimized the

Ra values are obtained based on the response table of GRG. It can be visualized from

table 8 that the optimal performance characteristics can be obtained from the level

A1B3C1D2 which means the maximum MRR value with better surface integrity can be

attained for copper surface composite with 5 volume fraction of BN dispersed at

machining parameters PulseON (130 µs), PulseOFF (40 µs), and WireFR (6 m/min). The

19
MRR and Ra values for the optimal combination of the process parameters are 20.19

mm3/min and 3.01 µs respectively. It can be seen that the MRR value has an increment

and at the same time a minimal Ra value thereby proving that the same optimal condition

can henceforth be used for machining copper-BN surface composites and thereby achieve

better performance characteristics.

CONCLUSIONS

Copper Surface composites with varying volume percentage of BN particles was

developed through FSP and the WEDM process conducted on it over an L27 OA trials

showcased the below given results.

BN particles have a significant effect on governing the MRR and Ra values along

with the WEDM machining parameters which includes PulseON, PulseOFF, and WireFR.

Lower values of BN particles volume fractions, PulseOFF along with higher

PulseON, and WireFR showcased higher MRR values while better surface integrity was

achieved at lower values of BN volume fractions, PulseON, and WireFR at higher PulseOFF

value.

WireFR had a minimal significance in governing the MRR and Ra values

The optimal combination of four control factors to achieve better MRR values

with minimal Ra value was obtained through Grey Relational Analysis and proved to be

achieved for Cu-BN surface composite with 5 vol% of BN at control factors, PulseON

(130 µs), PulseOFF (40 µs), and WireFR (6 m/min).

A mathematical relationship for MRR and Ra was developed effectively based on

its four control factors in this research and fitting of the same was carried out.

20
REFERENCES

1. Wu,Z.; Kang, P.C.; Wu, G.H.; Guo, Q.; Chen, G.Q.; Jiang, L.T. The effect of

interface modification on fracture behavior of tungsten fiber reinforced copper matrix

composites. Materials Science and Engineering A 2012, 536, 45–48.

2. Jafari, J.; Givi, M.K.B.; Barmouz, M. Mechanical and microstructural

characterization of Cu/CNT nanocomposite layers fabricated via friction stir processing.

International Journal of Advanced Manufacturing Technology 2015, 78(1–4), 199–209.

3. Titus Thankachan.; Soorya Prakash, K. Microstructural, mechanical and

tribological behavior of aluminum nitride reinforced copper surface composites

fabricated through friction stir processing route. Materials Science and Engineering: A

2017, 688, 301–308.

4. Titus Thankachan.; Soorya Prakash, K.; Kavimani V. Investigations on the effect

of friction stir processing on Cu-BN surface composites, Materials and Manufacturing

Processes 2017, doi: 10.1080/10426914.2017.1291952

5. Pramanik, A.; Basak, A.K.; Islam, M.N. Effect of reinforced particle size on wire

EDM of MMCs. International Journal of Machining and Machinability of Materials

2015, 17(2), 139-149.

6. Padhi, P.C.; Mahapatra, S.S.; Yadav, S.N.; Tripathy, D.K. Optimization of

Correlated Quality Characteristics in WEDM Process using Taguchi Approach Coupled

with Principal Component Analysis. Journal for Manufacturing Science & Production

2013, 13(3), 199–208.

21
7. Zhang, G.; Zhang, Z.; · Ming, W.; Guo, J.; Shao, X. The multi-objective

optimization of medium-speed WEDM process parameters for machining SKD11 steel

by the hybrid method of RSM and NSGA-II. International Journal of Advanced

Manufacturing Technology 2014, 70(9–12), 2097–2109.

8. Baraskar, S.S.; Banwait, S.S.; Laroiya, S.C. Multiobjective Optimization of

Electrical Discharge Machining Process Using a Hybrid Method. Materials and

Manufacturing Processes 2013, 28(4), 348–354.

9. Dhobe, M.M.; Chopde, I.K.; Gogte, C.L. Investigations on Surface Characteristics

of Heat Treated Tool Steel after Wire Electro-Discharge Machining. Materials and

Manufacturing Processes 2013, 28(10), 1143–1146.

10. Rao, T.B.; Krishna, A.G. Principal Component Analysis of Correlated WEDM

Performance Characteristics during Machining ZC63/SiCP MMCs. Journal for

Manufacturing Science and Production 2014, 14(1), 1–10.

11. Rao, T.B.; Krishna, A.G. Selection of optimal process parameters in WEDM

while machining Al7075/SiCp metal matrix composites. International Journal of

Advanced Manufacturing Technology 2014, 73(1–4), 299–314.

12. Sivaprakasam, P.; Hariharan, P.; Gowri, S. Optimization of Micro-WEDM

Process of Aluminum Matrix Composite (A413-B4C): A Response Surface Approach.

Materials and Manufacturing Processes 2013, 28(July 2014), 1340–1347.

13. Yue, T. M.; Dai, Y.; Lau W. S. An Examination of Wire Electrical Discharge

Machining (WEDM) of Al2O3 Particulate Reinforced Aluminum Based Composites.

Materials and Manufacturing Processes 1996, 11(3), 341-350.

22
14. Ramakrishnan, R.; Karunamoorthy, L. Modeling and multi-response optimization

of Inconel 718 on machining of CNC WEDM process. Journal of Materials Processing

Technology 2008, 207(1–3), 343–349.

15. Varun, A.; Venkaiah, N. Simultaneous optimization of WEDM responses using

grey relational analysis coupled with genetic algorithm while machining EN 353.

International Journal of Advanced Manufacturing Technology 2014, 76(1–4), 675–690.

16. Jangra, K.; Grover, S.; Aggarwal, A. Optimization of multi machining

characteristics in WEDM of WC-5.3%Co composite using integrated approach of

Taguchi, GRA and entropy method. Frontiers of Mechanical Engineering 2012, 7(3),

288–299.

17. Kumar, A.; Kumar, V.; Kumar, J. Semi-empirical model on MRR and overcut in

WEDM process of pure titanium using multi-objective desirability approach. Journal of

the Brazilian Society of Mechanical Sciences and Engineering 2015, 37(2), 689–721.

18. Saha, A.; Mondal, S.C. Multi-objective optimization in WEDM process of

nanostructured hardfacing materials through hybrid techniques. Measurement: Journal of

the International Measurement Confederation 2016, 94, 46–59.

19. Gauri, S.K.; Chakraborty, S. Multi-response optimisation of WEDM process

using principal component analysis. International Journal of Advanced Manufacturing

Technology 2009, 41, 741–748.

20. Chalisgaonkar, R.; Kumar, J. Optimization of WEDM process of pure titanium

with multiple performance characteristics using Taguchi’s DOE approach and utility

concept. Frontiers of Mechanical Engineering 2013, 8(2), 201–214.

23
21. Gopal, P.M.; Soorya Prakash, K.; Jayaraj, S. WEDM of Mg/CRT/BN

Composites: Effect of Materials and Machining Parameters. Materials and

Manufacturing Processes 2017, 1-8. doi: 10.1080/10426914.2017.1279316

22. Bobbili, R.; Madhu, V.; Gogia, A.K. Effect of Wire-EDM Machining Parameters

on Surface Roughness and Material Removal Rate of High Strength Armor Steel.

Materials and Manufacturing Processes 2013, 28, 364–368.

23. Hwa Yan, B.; Chung Tsai, H.; Yuan Huang, F.; Chorng Lee, L. Examination of

wire electrical discharge machining of Al2O3p/6061Al composites. International Journal

of Machine Tools and Manufacture 2005, 45(3), 251–259.

24. Garg, R.K.; Singh, K.K.; Anish Sachdeva, A.; Sharma, V.S.; Ojha, K.; Singh,

S.Review of research work in sinking EDM and WEDM on metal matrix composite

materials. The International Journal of Advanced Manufacturing Technology 2010,

50(5–8), 611–624.

25. Satishkumar, D.; M. Kanthababu, M.; V. Vajjiravelu, V.; Anburaj, R.; Thirumalai

Sundarrajan, N.; Arul, H. Investigation of wire electrical discharge machining

characteristics of Al6063/SiCp composites. International Journal of Advanced

Manufacturing Technology 2011, 56(9–12), 975–986.

26. Garg, S.K.; Manna, A.; Jain, A. An Investigation on Machinability of Al/10 %

ZrO2(P)-Metal Matrix Composite by WEDM and Parametric Optimization Using

Desirability Function Approach. Arabian Journal for Science and Engineering 2014,

39(4), pp.3251–3270.

27. Suresh Kumar,S.; Uthayakumar, M.; Thirumalai Kumaran, S.; Parameswaran, P.;

Mohandas, E.; Kempulraj, G.; Ramesh Babu, B.S.; Natarajan. S.A. Parametric

24
optimization of wire electrical discharge machining on aluminium based composites

through grey relational analysis. Journal of Manufacturing Processes 2015, 20, 33–39.

25
Table 1. Hardness and Density values for developed surface composites

Sl. No Specimen Hardness (HV) Density (gm/cm3)

1 Copper+ 5 Vol% BN 73.6 8.92

2 Copper+ 10 Vol% BN 74.1 8.96

3 Copper+ 15 Vol% BN 76.3 9.08

26
Table 2. Levels of Control Factors

Sl. No Control Factors Symbol Unit Level I Level I Level III

1 Volume Fraction of BN A % 5 10 15

2 PulseON B µs 120 125 130

3 PulseOFF C µs 40 45 50

4 WireFR D m/min 5 6 7

27
Table 3. L27 Array with Control Factors, Responses and their SN Ratios

Sl.No Control Factors Responses SN Ratio

Volume PulseON PulseOFF WireFR MRR Ra MRR Ra

Fraction (%) (µs) (µs) (m/min) (mm3/min) (µs)

1 5 120 40 5 12.68 2.83 22.06239 -8.8496

2 5 120 45 6 14.07 2.82 22.96588 -9.00498

3 5 120 50 7 10.37 2.68 20.31558 -8.5627

4 5 125 40 6 18.55 2.89 25.36688 -9.21796

5 5 125 45 7 17.47 2.82 24.84586 -9.00498

6 5 125 50 5 12.88 2.75 22.19832 -8.59505

7 5 130 40 7 20.46 3.02 26.21811 -9.60014

8 5 130 45 5 17.49 3.05 24.8558 -9.51342

9 5 130 50 6 17.14 2.94 24.68022 -9.36695

10 10 120 40 5 11.26 2.91 21.03077 -9.0969

11 10 120 45 6 12.42 2.93 21.88243 -9.33735

12 10 120 50 7 8.88 2.78 18.96826 -8.8809

13 10 125 40 6 17.06 3 24.63958 -9.54243

14 10 125 45 7 15.27 2.89 23.67678 -9.21796

15 10 125 50 5 10.62 2.78 20.52249 -8.69138

16 10 130 40 7 17.5 3.08 24.86076 -9.77101

17 10 130 45 5 15.09 3.09 23.57378 -9.62885

18 10 130 50 6 14.5 2.95 23.22736 -9.39644

19 15 120 40 5 9.62 2.99 19.6635 -9.33735

28
20 15 120 45 6 10.43 2.94 20.36569 -9.36695

21 15 120 50 7 7.22 2.8 17.17074 -8.94316

22 15 125 40 6 15.57 3.06 23.84577 -9.71443

23 15 125 45 7 12.54 2.97 21.96595 -9.45513

24 15 125 50 5 8.07 2.83 18.13747 -8.8496

25 15 130 40 7 15.08 3.17 23.56803 -10.0212

26 15 130 45 5 12.58 3.12 21.99361 -9.71443

27 15 130 50 6 12.08 3.01 21.64134 -9.57133

29
Table 4. Experimental Parameters

Sl. No Experimental Facility and Machining Parameters Specifications

1 Peak Current 10 A

2 Gap Voltage 20 V

3 PulseON 120, 125, 130 µs

4 PulseOFF 40, 45, 50 µs

5 Wire Electrode Material Brass

6 Wire Electrode Diameter 0.25 mm

7 Wire Tension 8N

8 Wire Feed Rate (WireFR) 5,6,7 m/min

9 Dielectric Fluid De-ionized water

10 Work Piece Height 6 mm

30
Table 5. Analysis of Variance for MRR

Source DF Seq SS Adj SS Adj MS F P Contribution%

Volume Fraction 2 79.900 79.900 39.950 174.93 0.000 26.2

PulseON 2 117.822 117.822 58.911 257.96 0.000 38.65

PulseOFF 2 76.347 76.347 38.174 167.15 0.000 25.03

WireFR 2 26.786 26.786 13.393 58.64 0.000 8.78

Error 18 4.111 4.111 0.228 1.35

Total 26 304.966

31
Table 6. Analysis of Variance for Surface Roughness

Source DF Seq SS Adj SS Adj MS F P Contribution%

Volume Fraction 2 0.06632 0.06632 0.03316 51.75 0.000 16.46

PulseON 2 0.19379 0.19379 0.09689 151.22 0.000 48.1

PulseOFF 2 0.12516 0.12516 0.06258 97.67 0.000 31.07

WireFR 2 0.02970 0.02970 0.01485 23.17 0.000 7.37

Error 18 0.01153 0.01153 0.00064 2.86

Total 26 0.40290

32
Table 7. Normalized SN values, GRC, GRG, Rank

Sl.No Normalized Values GRC GRG Rank

MRR Ra MRR Ra

1 0.54067 0.19670 0.52119 0.38364 0.4524 12

2 0.64053 0.30324 0.58175 0.41779 0.4997 7

3 0.34759 0 0.43387 0.33333 0.3836 2

4 0.90591 0.44927 0.84162 0.47586 0.6587 4

5 0.84832 0.30324 0.76725 0.41779 0.5925 3

6 0.55569 0.02218 0.5294 0.33833 0.4339 5

7 1 0.71130 1 0.63396 0.8169 1

8 0.84942 0.65184 0.76855 0.58951 0.6790 11

9 0.83001 0.55142 0.74628 0.52710 0.6366 6

10 0.42664 0.36626 0.4658 0.44102 0.4534 20

11 0.5207 0.53112 0.51061 0.51606 0.5133 19

12 0.19867 0.21816 0.38422 0.39006 0.3871 13

13 0.82552 0.67173 0.74131 0.60367 0.6724 10

14 0.71910 0.4492 0.64029 0.47586 0.5580 9

15 0.37046 0.08822 0.44266 0.35415 0.3984 8

16 0.84997 0.82846 0.76919 0.74455 0.7568 14

17 0.70772 0.73099 0.63109 0.65018 0.6406 21

18 0.66943 0.57164 0.60199 0.53858 0.5702 16

19 0.27552 0.53112 0.40833 0.51606 0.4622 26

20 0.35313 0.55142 0.43597 0.52710 0.4815 24

33
21 0 0.26085 0.33333 0.40350 0.3684 15

22 0.73778 0.78966 0.65598 0.70389 0.6799 18

23 0.53001 0.61188 0.5154 0.56298 0.5392 22

24 0.10685 0.19670 0.35889 0.38364 0.3712 17

25 0.70708 1 0.63058 1 0.8152 23

26 0.53306 0.78966 0.517 0.70389 0.6104 27

27 0.49413 0.69155 0.49708 0.61847 0.5577 25

34
Table 8. Response table for GRG

Sl. No Control Factors Level I Level I Level III Delta Rank

1 Volume Fraction of BN 0.5726* 0.5501 0.5429 0.0297 4

2 PulseON 0.4446 0.5449 0.6760* 0.2314 1

3 PulseOFF 0.6409* 0.5683 0.4564 0.1845 2

4 WireFR 0.5002 0.5856* 0.5798 0.0854 3

35
Figure 1. Steps in FSP (a) Copper specimen (b) cutting a groove, (c) compacting the
groove with ceramic particles, (d) processing using a pinless tool and (e) processing using
a tool with pin.

36
Figure 2. SEM images for (a) Cu+5 Vol.% BN (b) Cu+15 Vol.%BN

37
Figure 3. Experimental facility and specimen cutting procedure

38
Figure 4. SN ratio response graph for MRR

39
Figure 5. SN ratio response graph for Ra

40
Figure 6. Experimental Vs Predicted MRR

41
Figure 7. Experimental Vs Predicted Ra

42