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

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Abstract

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.

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Authors and Affiliations

  1. Department of Mechanical Engineering and Centre for Surface Engineering, Kalasalingam Academy of Research and Education, Krishnankoil, Virudhunagar Dist., 626126, Tamil Nadu, India

    S. R. Stalin, M. Adam Khan & J. T. Winowlin Jappes

  2. Department of Computer Science and Engineering and Centre for Surface Engineering, Kalasalingam Academy of Research and Education, Krishnankoil, Virudhunagar Dist., 626126, Tamil Nadu, India

    N. C. Brintha

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  1. S. R. Stalin
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  2. M. Adam Khan
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  3. J. T. Winowlin Jappes
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  4. N. C. Brintha
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Contributions

Stalin - Drafted the manuscript with experimentation Adam - Developed the problem statement and methodology Winowlin - Supported in Data inference and findings Brintha - Supported in tuning the manuscript

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Correspondence to M. Adam Khan.

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Stalin, S.R., Khan, M.A., Jappes, J.T.W. et al. Experiment assessment and Adam gene algorithm to optimize the process parameter of wire spark erosion material removal while machining nickel alloy. Multiscale and Multidiscip. Model. Exp. and Des. (2024). https://doi.org/10.1007/s41939-023-00343-w

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