Name:-Sumanta das Roll:-1011701010 4th year Department of Production Engineering Jadavpur university

Introduction
Electric discharge machining(EDM) is an electro-thermal process, is

one of the most popular non-conventional machining process. This technique has been developed in the late 1940s. The process is based on removing material from a part by means of a series of repeated electric discharges between the electrode and the work piece in the presence of a dielectric fluid. The material is removed with the erosive effect of the electrical discharges from tool and work piece. It has been used to manufacture a wide variety of items, such as moulds, die , automotive ,aerospace and surgical components. Materials of any hardness can be cut as long as the material can conduct electricity.

Electric discharge machining(EDM)

Process parameters of EDM

Discharge Voltage
Discharge voltage in EDM is related to the spark gap and brake-down strength of the dielectric. Before current can flow, the open gap voltage increases until it has created an ionization path through the dielectric. Once the current starts to flow, voltage drops and stabilizes at the working gap level. Higher voltage settings increase the gap which improves the flushing conditions, and helps to stabilize the cut. MRR, tool wear rate (TWR) and surface roughness increases, by increasing open circuit voltage, because electric field strength increases.

Process parameters of EDM

Peak Current
This is the amount of power used in discharge machining measured in units of amperage, and is the most important machining parameter in EDM. During each on-time pulse, the current increases until it reaches a preset level, which is expressed as the peak current. In both die-sinking and wire-EDM applications, the maximum amount of amperage is governed by the surface area of the cut. Higher currents will improve MRR, but at the cost of surface finish and tool wear.

Process parameters of EDM

Pulse on-time and Pulse off-time
Each cycle has an on-time and off-time that is expressed in units of microseconds. Since all the work is done during on-time, the duration of these pulses and the number of cycles per second (frequency) are important. Metal removal is directly proportional to the amount of energy applied during the on-time. Pulse on-time is commonly referred to as pulse duration and pulse offtime is called pulse interval. With longer pulse duration, more work piece material will be melted away.

What is optimization
Optimization is the mathematical discipline which is concerned with

finding the maxima and minima of functions, possibly subject to constraints. The formulation of optimal design problems involves design variables, constraints , objective function and variable bounds.

Objective of optimization of EDM

Maximize the material removal rate(MRR),

MRR represents the volume or mass of work piece removed in unit time. Minimize the surface roughness(Ra) Ra is the roughness average measured using taly-surf.

What is annealing
At high temperature, the atoms in the molten metal can freely move with respect to each other, but as the temperature is reduced, the movement of the atoms gets restricted. The atoms start to get ordered and finally form crystals having the minimum possible energy. however the formation of the crystal mostly depends on the cooling rate, if temperature is reduced at a very fast rate, the crystalline state may not be achieved at all, instead the system may end up with a polycrystalline state, which have a higher energy state than the crystalline. therefore ,in order to achieve the absolute minimum energy state, the temperature is to be reduced at a slow rate. the process of slow cooling is known as annealing in metallurgical practice.

What is Simulated annealing

The simulated annealing procedure simulates the process of slow of molten metal to achieve the minimum function value in minimization problem. the cooling phenomenon is simulated by controlling a temperature-like parameter using the concept of Boltzmann probability Distribution. According to this a system in thermal equilibrium at a temperature T has its energy distributed probabilistically as P(E)=exp(-E/KT).where K is the Boltzmann constant. By controlling the temperature T and assuming that the search process follows the Boltzmann probability distribution, the convergence of an algorithm can be achieved. Simulated annealing algorithm begins with an initial point and a high temperature T. A second point is created at random in the vicinity of the initial point and the difference in the function values dE at these two points is calculated. If the second point has a smaller function value, the point is accepted; otherwise the point is accepted with a probability exp(-dE/T).This completes one cycle of the simulated annealing procedure.

.
In the next cycle, again another point is created at random in the

neighbourhood of the updated current point and the Metropolis algorithm is used to accept or reject the point. in order to simulate the thermal equilibrium at every temperature, a number of points (n) are usually tested at a particular temperature, before reducing the temperature. the algorithm is terminated when a sufficient small temperature is obtained or a desirable minimal change in function value is observed. the initial temperature T and the number of iterations N performed at every temperature are two important parameters, which govern the successful working of the simulated annealing procedure.

Simulated annealing algorithm

1.Choose a randomly generated initial point x^0 , a termination temperature Tlow. Also set number of iterations (N) to be performed at a particular temperature and iteration counter t=0. 2.Evaluate the value of objective function E1=f(X^t). 3.Calculate a neighbourhood point X^(t+1) using random perturbation and evaluate objective function at X^(t+1) as E2=f(X^t+1). 4.Calculate dE=E2-E1. 5.(i) if dE<0, accept the point.That is X^t=X^t+1 and E1=E2.set t=t+1 and go to step -6 (ii) if dE>=0,creat random number r in the range (0,1) and check whether r<=exp(-dE/T).if satisfied then set t=t+1 and go to step -6.else go to step-3 6. If t>N go to step-7 7. Reduce the temperature periodically by factor k1 according to

T=k1T and go to step-3. 8. If T<=Tlow then terminate the process.

Determination of optimal cutting conditions by Simulated annealing

Simulated annealing(SA) optimization scheme is employed to solve the multi-objective formulation. the objective of optimization are (i)maximize the material removal rate(MRR),and (ii)minimize the surface roughness value. the process parameters considered in experiments are Discharge current(I), Source Voltage(V),Pulse-on time(Ton),Pulse-off time(Toff). For optimization the objective function is defined as Minimize f( I , V , Ton , Toff ) = -W1MRR + W2Ra Subjected to 5 <=I<=50 80<=V<=200 5<=Ton<=800 10<=Toff<=400 W1 and W2 are weighing parameters required to make the function nondimensional.

.
The scheme of constrained optimization in this multi-objective case is presented in the flowchart in the next slide. Simulated annealing algorithm is implemented with the following parameters. Initial temperature T=400 Termination criterion Tlow=10^-5 Boltzmann constant K=10 Cooling rate K1=0.9 Number of cycles per temperature N= 100

Proposed methodology

Optimization results
Trial 1 2 3 I 16.14 9.39 35.09 V 152.83 144.63 141.69 Ton 306.72 414.01 Toff 241.17 113.93 MRR 54.83 52.13 53.12 Ra 2.16 2.09 2.47

666.43 335.59

4
5 6 7 8

8.79
39.0 13.67 33.90 7.29

146.82
149.02 105.17 127.88 83.51

325.25
555.27 412.22 156.29

292.07
362.28 109.58 108.65

55.17
54.82 51.90 54.93 53.31

2.85
2.63 2.01 2.07 2.09

69.026 153.41

9
10

31.24
23.01

148.32
115.61

474.96
224.67

277.45
247.62

54.83
54.43

2.31
2.86

Conclusion
Simulated annealing uses single point search method. Simulated annealing is a global optimization technique. Simulated annealing distinguishes between two local optima. Simulated Annealing guarantees a convergence upon running

sufficiently large number of iterations. this method can be extended to consider more number of operating parameters in studying their effect on material removal rates and surface roughness values

References
Optimization of electric discharge machining using simulated

annealing . Seung-Han Yang, j.srinivas,sekar Mohan,Dong-Mok Lee,sree Balaji Optimization for engineering design by Kalyanmoy Deb Surface modification by electrial discharge machining, sanjeev kumar,Rupinder singh,T.P.singh, B.L.sethi

Thank you