Articles written in Sadhana

    • Mathematical modeling and analysis of WEDM machining parameters of nickel-based super alloy using response surface methodology


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      Inconel 625 is one of the most versatile nickel-based super alloy used in the aerospace, automobile, chemical processing, oil refining, marine, waste treatment, pulp and paper, and power industries. Wire electrical discharge machining (WEDM) is the process considered in the present text for machining of Inconel 625 as it can provide an effective solution for machining ultra-hard, high-strength and temperature-resistant materials and alloys, overcoming the constraints of the conventional processes. The present work is mainly focused on the analysis and optimization of the WEDM process parameters of Inconel 625. The four machining parameters, that is, pulse on time, pulse off time, spark gap voltage and wire feed have been varied to investigate their effects onthree output responses, such as cutting speed, gap current, and surface roughness. Response surface methodology was used to develop the experimental models. The parametric analysis-based results revealed that pulse on time and pulse off time were significant, spark gap voltage is the least significant, and wire feed as a single factor is insignificant. Multi-objective optimization technique was employed using desirability approach to obtain theoptimal parameters setting. Furthermore, surface topography in terms of machining parameters revealed that pulse on time and pulse off time significantly deteriorate the surface of the machined samples, which produce thedeeper, wider overlapping craters and globules of debris.

    • Investigation of biocompatible implant material through WEDM process using RSM modeling hybrid with the machine learning algorithm


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      CP-Ti-G2 (Commercially pure titanium grade-2) has become the preferred biocompatible material for various devices mainly used in orthopedic and dental implants and it is also used in aviation and aircraft. While CP-Ti deals with good ductility, higher stiffness, and fatigue resistance. The novelty of present researchwork was to create a rough surface on CP-Ti-G2 through the WEDM process. Further, this rough surface was used in the development of bone marrow cells on it. Propagation and diversity of bone marrow cells were applied in dental implant osteointegration applications. Six WEDM factors were analyzed through the BBD design of the experiment. 54 trial experiments were conducted to observe the MRR and SR output responses. After machining, surface topography was examined through SEM and EDX. ANOVA was applied to analyze the significance of factors. It was observed that POT (pulse on time), POFT (pulse off time), PC (peak current), and SGV (spark gap voltage) are the most significant factors. The WEDM factors have also been significantlydeteriorating the microstructure of machined samples remarkably deeper, wider craters, globules of debris, and micro cracks. A multi-objective optimization ‘desirability’ function was applied to obtain the optimal solutions by numerical and supervised machine learning algorithms. They lead to the reflection of parametric machine learning algorithms to surmise about the effectiveness of WEDM process. The results show a good agreement between actual and predicted values.

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