International Journal of Advances in Science and Technology, Vol. 4, No.

1, 2012

Optimization of operating Parameters in wire Electric discharge machining for Improving quality using Genetic Algorithm
L.Savadamuthu 1 S.Muthu 2 K.Thrumalai Kannan 3
1

Assistant Professor, SNS College of Technology, Affiliated to Anna University Coimbatore, India

savudamuthu@gmail.com
2 3

Principal, Srividya College of Engineering and Technology, Affiliated to Anna University Tirunelveli, India Assistant Professor, SNS College of Technology, Affiliated to Anna University Coimbatore, India thirumalyai_kannan@yahoo.co.in

Abstract
Wire electric discharge machining (WEDM) process is one of the important nontraditional machining processes which is used to machine hard materials, complex shapes and contours which are difficult by conventional methods. In this paper genetic algorithm based optimization procedures have been developed to optimize machining parameters viz., machining speed, pulse on time, pulse off time, and peak current by using two response equations for material removal rate and surface roughness. The objective function considered for optimization is maximization of material removal rate and minimization of surface roughness. In order to obtain output result of this GA Technique a computer program is al so developed in C language. Keywords: WEDM, GA Technique, Optimization, Machining parameters.

1. Introduction
In modern industry the goal is to manufacture low cost, high quality products in short time. Automated and flexible manufacturing systems are employed for that purpose along with computerized numerical control (CNC) machines that are capable of achieving high accuracy and very low processing time. The generic term EDM (Electrical Discharge Machining) can be applied to any machining process that uses an electrode to remove metal, or any other conductive material, from a work piece by generating sparks between conducting surfaces. During this process, energy from the sparks created between the electrode and the work piece is dissipated by the melting and vaporizing of the work piece material. All this being performed in a dielectric fluid to prevent premature spark discharge. Wire electric discharge machining (WEDM) process becomes an important non-traditional machining process. Wire EDM is a method to cut conductive materials using a thin electrode wire which feeds from reel to reel. Wire EDM uses sparks of electrical energy to progressively erode an electrically conductive work-piece. There is no physical contact between the wire and the part being machined. Rather, the wire is charged to a voltage very rapidly. This wire is surrounded by de-ionized water. When the voltage reaches the correct level, a spark jumps the gap and melts a small portion of the work piece. The de-ionized water cools and flushes away the small particles from the gap. The hardness of the work piece material has no detrimental effect on the cutting speed. Wire EDM process widely used in aerospace, nuclear and automobile industries. This is because the Wire EDM process provides an effective solution for machining hard materials with intricate shapes, which are not possible by conventional machining methods. The economy of machining mainly depends on operating parameters in Wire EDM. Optimization of operating

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International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 parameters is an important step in machining particularly for operating unconventional machining procedure like Wire EDM.

2. Literature Review
A genetic algorithm is one of the search techniques which applies the principles of evolution found in nature to the problem of finding an optimal solution to a Solver problem. In a genetic algorithm the problem is encoded in a series of bit strings that are manipulated by the algorithm and the decision variables and problem functions are used directly. Ajay joneja and Pang kingwah [1]used genetic algorithm for Path Planning in Rapid Prototyping. Dr.VVS.Kesavarao and T.Hari Krishna [2] used genetic algorithm to solve Vehicle Routing problem.Prof.Uday.J.Amonkar & Rajesh S. Prabhu Gaonkar [3] applied genetic algorithm to solve Transportation problem. K.Thangadrai, J.Jerald, P.Sateesh, and Dr.R.Saravanan [4] proposed a method for optimization of operating parameters in Wire Electric Discharge Machining using Particle Swarm Optimization and Meme tic Algorithm. In this paper Genetic Algorithm is used to solve the same.

3. Problem Definition
In this paper, we have optimized the operating parameters under Maximum Material removal rate and Minimum surface roughness by taking two separate objective functions. Here four operating parameters are considered viz., Machining speed, Pulse on time, Pulse off time and Peak current with defined ranges in Wire Electric Discharge Machining. The Mathematical model proposed by A.Thillaivanan, P.Asokan and G.Prabhaharan is used in this work.The operating parameters and ranges considered for optimization in this work are given below. Operating parameters of the WEDM process s.no 1 2 3 4 Operating Parameters Machining speed (A) Pulse on time (B) Pulse off time (C) Peak current (D) Range 1.00-1.75 mm/min 15-25 s 15-25 s 3-4 amp

Mathematical model of WEDM Response Equation for MRR MRR[i]=1.6184-(0.0404*((pow((dv_A[i]-1.375),2)/0.01)-(8/12)))-(0.0138*(dv_B[i] 20))(0.0465*((pow((dv_D[i]-3.5),2))/.25)-(8/12)); From the above response equation for MRR out of four input operating parameters considered only three parameters namely Machining speed, Pulse on time, and Peak current are significant in material removal rate. Response Equation for Surface Roughness RA[i]=(1.6592)+(0.687*(dv_A[i]-1.375)*(1-1.407*(dv_D[i]-3.5)))-(0.0061*(dv_C[i]20))+(0.0374*((((dv_D[i]-3.5)*(dv_D[i]-3.5))/0.25)-(8/12))); Similarly From the above response equation for RA out of four input operating parameters considered only three parameters namely Machining speed, Pulse off time, and Peak current are significant in surface roughness.

4. Methodology
In this paper process parameters of Wire Electric Discharge Machining is being optimized by using genetic algorithm as a tool. In this paper the ranges of parameters are taken from the paper published in the journal Manufacturing Technology Today by K.Thangadurai, Jerald, Satheesh, and Dr.R.Saravanan. In this paper there are two objective functions are selected, one is Maximization type

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International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 and other is Minimization type that is Maximize material removal rate& minimize the surface roughness. The corresponding objective functions also taken from same paper. Here the methodology is explained for maximize the MRR value. The same methodology is also used to minimize the RA value. There is an only difference is objective function.

Algorithm Step1: Specify the parameters to be considered with ranges. Step2: Select the objective function. Step3: Generate 21 digit binary number 30 times. Step4: Decode that binary numbers in to decoded values and
Substitute that decoded values in objective function. Decoded value = (decimal value*accuracy)+minimum value Accuracy=(maximum-minimum)/((2^n)-1) Where n=no of bits used to representing an each parameter

Step5: Reproduction Step6: Cross over Step7: Mutation Step8: Assign the result of mutation as the input of Initial Population and repeat the process unto Step 7 for N number of iterations. Step9: Select the biggest value of MRR Step10: Decode that binary digits in to corresponding decoded Values. Store the decoded values and MRR value. Initially specify the parameter ranges and n value. Genetic algorithms work is done with the help of following four operators, Initial population Reproduction Cross over Mutation Initial population In this initial population generate 21 digit binary number 30 times randomly. In that 21 bits first 7 bits represent the parameter A, second 7 bits represent the parameter B and third 7 bits represent the parameter D. 000110101001111000011 101100101110000011000 111000100101101111000 111001111011001000011 001010101010010001010 111100011101001100100 011010001111111101110 001111101110101111101 100101010101011000010 010100010000011101001 110111000100110011010 111111010111110101011 100100110100110011110 101101100111101110101 001111111101011101110 100011110111101100011 100001101101001010101 111000000000000011011 011101111011010000110 011000110111000010000 100000011110001101110 100000001010110001011 011000101100110111110 100101110101100010011

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International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 100000110000101010110 000110000000111000000 100111111111001110011 000000000011010100001 000110110111011001011 111110001011001110010 Reproduction In this stage reproduce the same binary string from initial population. Some strings may be reproduced more than one time. Some may not be reproduced. This reproduction is based on the fitness. Here the binary strings are decoded to decoded values by using the following formulae.
Decoded value=(decimal value*accuracy)+minimum value--------(1) Accuracy=(maximum value-minimum value)/((2^n)-1)-------------(2)

Where n= No of bits used to represent an each parameter. 1.076772 18.070866 3.527559 1.285563 1.525591 19.409449 3.188976 1.516940 1.667323 16.732283 3.944882 1.281453 1.679134 23.503937 3.527559 1.196215 1.124016 18.228346 3.078740 1.355349 1.708661 24.133858 3.787402 1.096216 1.307087 19.960630 3.866142 1.575375 1.183071 19.566929 3.984252 1.431939 1.437008 21.692913 3.519685 1.579432 1.236220 20.118111 3.826772 1.519100 1.649606 16.496063 3.204724 1.345886 1.744094 22.480314 3.338583 1.028953 1.431102 21.535433 3.236220 1.571553 1.537402 17.362206 3.921260 1.515242 1.183071 24.212599 3.866142 1.386510 1.419291 22.401575 3.779528 1.562800 1.395669 19.094488 3.669291 1.623839 1.661417 15.000000 3.212598 1.340615 1.348425 23.582678 3.047244 1.527978 1.289370 22.244095 3.125984 1.531789 1.377953 24.448818 3.866142 1.532036 1.377953 18.385826 3.086614 1.608855 1.289370 19.015747 3.488189 1.602334 1.442913 21.771654 3.149606 1.552481 1.383858 20.196850 3.677165 1.609528 1.070866 15.236220 3.503937 1.310448 1.466535 24.763779 3.905512 1.488224 1.000000 16.023623 3.259843 1.094421 1.076772 22.322834 3.590551 1.225502 1.732283 18.464567 3.897638 1.094467 Generate two random numbers N1&N2 between 1 to 30 with the accuracy of 1.Compare the corresponding MRR values and store the superior & inferior. Generate a random number N3 between 0 to1 with the accuracy of 0.01.If N3 is less than or equal to 0.75,copy the superior one else copy the inferior one. N1 22 6 3 5 N 2 21 16 12 18 (MRR)N 1 1.6023 1.5754 1.1962 1.0962 (MRR)N 2 1.6089 1.6238 1.5716 1.5280 N3 0.2200 0.1300 0.8300 0.2200 COPIED MRR 1.6089 1.6238 1.1962 1.5280

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30 17 29 19 9 20 13 2 21 15 13 18 15 16 8 25 29 1 17 20 20 27 24 2 27 8

21 7 26 14 22 16 13 1 4 26 1 5 18 14 18 8 27 23 22 7 23 23 8 6 24 12

3.5276 1.3406 1.0945 1.5318 1.5191 1.5320 1.5152 1.2815 1.6089 1.5628 1.5152 1.5280 1.5628 1.6238 1.5794 1.3104 1.0945 1.5169 1.3406 1.5320 1.5320 1.0944 1.6095 1.2815 1.0944 1.5794

1.6089 1.4319 1.4882 1.3865 1.6023 1.6238 1.5152 1.5169 1.3553 1.4882 1.5169 1.0962 1.5280 1.3865 1.5280 1.5794 1.0944 1.5525 1.6023 1.4319 1.5525 1.5525 1.5794 1.5754 1.6095 1.5716

International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 0.3900 1.5276 0.8800 0.1000 0.2400 0.1500 0.0700 0.3200 0.4300 0.7900 0.5200 0.8100 0.6700 0.1400 0.8400 0.2700 0.1600 0.9700 0.8900 0.1100 0.7300 0.7100 0.1100 0.3100 0.8200 0.0900 0.7300 1.3406 1.4882 1.5318 1.6023 1.6238 1.5152 1.5169 1.3553 1.5628 1.5152 1.5280 1.5628 1.3865 1.5794 1.5794 1.0944 1.5169 1.6023 1.5320 1.5525 1.5525 1.6095 1.2815 1.6095 1.5794

Copied MRR 1.608855 1.623839 1.196215 1.527978 1.340615 1.488224 1.531789 1.602334 1.623839 1.515242 1.516940 1.355349 1.562800 1.515242 1.527978 1.562800

Binary Strings 100000001010110001011 100001101101001010101 111001111011001000011 011101111011010000110 111000000000000011011 100111111111001110011 011000110111000010000 011000101100110111110 100001101101001010101 101101100111101110101 101100101110000011000 001010101010010001010 100011110111101100011 101101100111101110101 011101111011010000110 100011110111101100011

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1.386510 1.579432 1.579432 1.094421 1.516940 1.602334 1.532036 1.552481 1.552481 1.609528 1.281453 1.609528 1.579432

International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 001111111101011101110 100101010101011000010 100101010101011000010 000000000011010100001 101100101110000011000 011000101100110111110 100000011110001101110 100101110101100010011 100101110101100010011 100000110000101010110 111000100101101111000 100000110000101010110 100101010101011000010

Cross over This is the third stage of Genetic Algorithm. Before entering in to the cross over process should form pairs and decide which pairs are cross overed. First form pairs after that Generate a random number (N4) between 0 to 1 with the accuracy of 0.1 If random number N4 is less than or equal to 0.6, then that pair should under gone cross over process else that strings are copied to the next operation. After deciding the cross over pair then decides after which bit cross over takes place. For this purpose generate a random number (N5) between1 to 20 with the accuracy of 1. Then cross over the corresponding pair of strings after the N5th bit. This random number (N5) generation is repeated to 15 times. 0.800000(N4) 000110101001111000011 101100101110000011000 0.700000 111000100101101111000 111001111011001000011 0.400000 5(N5) 001010011101001100100 111100101010010001010 0.100000 10 011010001110101111101 001111101111111101110 0.600000 5 100100010000011101001 010101010101011000010 0.400000 8 110111000111110101011 111111010100110011010 0.400000 18 100100110100110011101 101101100111101110110 0.000000 4 001111110111101100011 100011111101011101110 0.900000 100001101101001010101 111000000000000011011 0.800000 011101111011010000110 011000110111000010000 0.300000 16 100000011110001101011 100000001010110001110

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International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 0.300000 11 011000101101100010011 100101110100110111110 0.900000 100000110000101010110 000110000000111000000 0.600000 0 000000000011010100001 100111111111001110011 0.800000 000110110111011001011 111110001011001110010 Mutation Mutation is the last operator of Genetic Algorithm. Mutation means change the corresponding bit position value as 0 to 1 or vise versa. Here first assign the value of Mutation probability (Pm).then decide how many number of bits (L) are going to mutate. This is calculated by the following formula. L=(Pm*30*21) Generate a random number (N6) between 1 to 630 with the accuracy of 1. Mutate the corresponding position (N6th) bit value. Then random generation is repeated for L times. After the mutation process is over then decodes those binary strings in to decoded values using the equations (1) & (2). Binary strings obtained from the mutation process are assigned as the input of Initial population, and then repeat the GA process for K number of generations. MRR value obtained in every mutation process is stored separately. Out of this stored MRR values select the biggest value that is the optimal solution. Then copy that MRR value and its corresponding decoded values. 1.076772 18.070866 3.527559 1.285563 1.525591 19.409449 3.188976 1.516940 1.667323 16.732283 3.944882 1.281453 1.679134 23.503937 3.527559 1.196215 1.118110 24.133858 3.787402 1.279380 1.714567 18.228346 3.078740 1.144006 1.307087 19.566929 3.984252 1.562126 1.183071 19.960630 3.866142 1.445188 1.425197 20.118111 3.826772 1.586729 1.248031 21.692913 3.519685 1.529837 1.649606 17.440945 3.338583 1.344218 1.744094 21.535433 3.204724 1.030622 1.431102 21.535433 3.228346 1.570769 1.537402 17.362206 3.929134 1.513996 1.183071 22.401575 3.779528 1.421904 1.419291 24.212599 3.866142 1.527406 1.395669 19.094488 3.669291 1.623839 1.661417 15.000000 3.212598 1.340615 1.348425 23.582678 3.047244 1.527978 1.289370 22.244095 3.125984 1.531789 1.377953 24.448818 3.842520 1.535150 1.377953 18.385826 3.110236 1.612384 1.289370 19.251968 3.149606 1.576263 1.442913 21.535433 3.488189 1.578552 1.383858 20.196850 3.677165 1.609528 1.070866 15.236220 3.503937 1.310448 1.000000 16.023623 3.259843 1.094421

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1.442913 1.076772 1.732283

International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 24.763779 3.905512 1.503441 22.322834 3.590551 1.225502 18.464567 3.897638 1.094467

Result of Biggest No 1.395669 19.094488 3.669291 1.623839 Software Development In order to obtain output result of this GA Technique a computer program was developed. A computer program is written in C language for optimize the process parameters of Wire Electric Discharge Machining. C programming is highly reliable, adoptable, and is very user friendly. The file which is used to run the program is MRR.c. There is a need to compile the file MRR.c for checking the sintaxial errors. Then execute the object file. After the execution is over the ranges of the process parameters are given. Then the final optimal result is printed. 5. Results and Discussion The following table shows the optimal operating parameters of Wire Electric Discharge Machining such as machining speed, pulse on time, pulse off time, and peak current obtained from genetic algorithm. The maximum value of MRR is 1.623839. The minimum value of RA is 1.425334. Machining speed(A) (mm/min) 1.395669 Machining speed(A) (mm/min) 1.159449 6. Conclusion In previous work, the authors have optimized the operating parameters by taking multiple objective functions. In this paper Genetic algorithm based procedures used to optimize Wire Electric Discharge Machining parameters viz machining speed, pulse on time, pulse off time, and peak current by taking two separate objective functions. In order to obtain output result of this GA Technique a computer program is also developed in C language. This optimization process is easy to use and very simple to implement. REFERENCES: [ 1] Ajay Joneja, Pang King Wah, Katta G.Murrty, Leung Chi Chitu, Tool Path optimization in Layered Manufacturing, IIE Transactions,Volume 29 1997 . [ 2] Ajay Joneja, Pang King Wah, Katta G.Murrty, Leung Chi Chitu, Tool Path optimization in Layered Manufacturing, IIE Transactions, Volume 34 / 2002. [3] Dr. V.V.S. Kesava Rao, and T. Hari Krishna, Vehicle Routing using Genetic Algorithm, .Int.j. of Industrial Engineering Journal. [4] S.Prabhu Gaonkar, Prof. Uday, J. Amonkar & Rajesh, An improved heuristic for initial solution of transportation problem .Int.j. of Manufacturing Technology Today. [5] K.Thangadrai, J.Jerald, P.Sateesh, Dr.R.Saravanan Optimization of operating parameters in Wire Electric Discharge Machining using Particle Swarm Optimization and Meme tic Algorithm .Int.j. of Manufacturing Technology Today. [6] R.Saravanan, P.Ashokan and K.Vijayakumar, Machining parameters optimization for turning cylindrical stock in to continuous finished profile using GA and SA .Int.j. Of Advanced Manufacturing Technology, 2002. Pulse on time(B) 19.094488 Pulse off time(C) 24.133858 Peak current(D) (Amp) 3.669291 Peak current(D) (Amp) 3.086614 MRR (mm/min) 1.623839 Surface roughness 1.425334

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International Journal of Advances in Science and Technology, Vol. 4, No.1, 2012 BIOGRAPHY

L.Savadamuthu received his Bachelor of Engineering degree in Mechanical Engineering from Government College of Technology, Bharathiar University, Coimbatore, India in 1997, Master of Engineering degree in Production Engineering from PSG College of Technology, Bharathiar University, Coimbatore, India in 2004. He is currently a Research Scholar in the department of Mechanical Engineering, Anna University, Chennai, India. He is a Life member of ISTE, and member of ISHRAE. He has vast industrial experience in various areas such as Designing Jigs and Fixtures, Development of Toolings for Special machines, preparation of Process sheet etc. Currently he is working as an Assistant Professor in the department of Mechanical Engineering, SNS College of Technology, Coimbatore, India. His areas of interest are Production Engineering, Process Planning and Cost estimation, Quality Management, Design of Toolings etc.

Dr.S.Muthu received his Bachelor of Engineering degree in Production Engineering from PSG College of Technology, Coimbatore, University of Madras,, India in 1978, Master of Engineering degree in Industrial Engineering from PSG College of Technology, Coimbatore, University of Madras, , India in 1980. He is a Life member of ISTE,IE and Fellow member in IIIE. He had 30years of academic experience at various capacities. Currently he is serving as a principal in Sri Vidya College of Engineering and Technology, Virudhunagar. He published 5 International Journals and presented 47 national and International Conferences. He has been guiding 14 Research scholars and his areas of interest are Production Engineering, Quality Management, Maintenance Managements etc.

K.Thirumalai Kannan received his Bachelor of Engineering degree in Mechanical Engineering from V.L.B.Janaki Ammal College of Engineering and Technology, Bharathiar University, Coimbatore, India in 1999, Master of Engineering degree in Engineering Design from Anna University of Technology Coimbatore , Coimbatore, India in 2011. He has long industrial and academic career of 12 years of experience at various capacities from Lecturer to Assistant professor Currently he is working as an Assistant Professor in the department of Mechanical Engineering, SNS College of Technology, Coimbatore, India. His areas of interest are Engineering Mechanics, Kinematics of machineries, Design of Transmission systems, Process Planning and Cost estimation, Design of machine elements, Robotics etc.

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