Experiment assessment and Adam gene algorithm to optimize the process parameter of wire spark erosion material removal while machining nickel alloy

• Published in: Multiscale and Multidisciplinary Modeling, Experiments and Design Experiments and Design, 2024-07, Vol.7 (3), p.2393-2400
• Main Authors: Stalin, S. R., Khan, M. Adam, Jappes, J. T. Winowlin, Brintha, N. C.
• Format: Article
• Language: English
• Subjects: Characterization and Evaluation of Materials; Engineering; Mathematical Applications in the Physical Sciences; Mechanical Engineering; Numerical and Computational Physics; Original Paper; Simulation; Solid Mechanics
• ISSN: 2520-8160; 2520-8179
• DOI: 10.1007/s41939-023-00343-w

The nickel-based superalloy, CM247 is machined using wire electro spark material removal process with three different levels of process parameters. The material removal rate and the surface finish are evaluated individually to assess the influence of process parameters. Maximum material removal is noticed with increase in pulse on duration and superior surface finish with average pulse on time. At 30 V and 120 μs in pulse on time, maximum material removal is noticed and better surface roughness as 2.211 μm. The machinability of the material depends on the duration of electro spark intensity generated during machining. Pulse on time has a maximum influence (53%) on surface roughness followed by the applied voltage (30%). In material removal, the applied voltage (87%) is a predominant factor. A modified genetic algorithm, mimic of iconic pair Adam and Eve is simulated to study the varying populations. From the optimization technique, a globally best process parameter is identified for the electro spark material removal of CM247 alloy. The optimal process condition is 18 V and 126 µs for applied voltage and pulse on time.