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Optimization of Electrical Discharge Machining of Titanium Alloy (Ti-6Al-4V) using Taguchi-DEAR Method

  • Jayamukhi Institute Of Technological Sci - Vikram Reddy Vaddi
  • JNTU CEH Manthani - Sridhar Reddy Ch
  • Show More
  • Technical Paper
  • 2018-28-0032
Published 2018-07-09 by SAE International in United States
Electrical discharge machining (EDM) process is widely used unconventional machining process in manufacturing industry for machining high hardness materials and to make dies of complex cavities. In this work experiments are carried out during electric discharge machining of Titanium alloy (Ti–6Al–4V). Taguchi L9 orthogonal array is used to conduct experiments. Process parameters, such as, peak current, pulse on time and pulse off time are chosen for this study. Whereas performance characteristics namely material removal rate (MRR), tool wear rate (TWR) and surface roughness (SR) are selected for this study. The significance of process parameters on performance characteristics is analyzed. The objective of present work is to find optimal combination of parameters that gives maximum MRR and minimum TWR and SR simultaneously. Taguchi-data envelopment analysis–based ranking method is used for above multi-response optimization Keywords: Data envelopment analysis–based ranking, Material removal rate, Surface roughness, Tool wear rate,

A Comparative study on Machinability Characteristics in dry machining of INCONEL X750 alloy using coated carbide inserts

  • Srisai Ram Engineering College - Vetri Velmurugan Kannan
  • Vellore Institute of Technology - Venkatesan Kannan
  • Technical Paper
  • 2018-28-0031
Published 2018-07-09 by SAE International in United States
This paper present the machinability investigation of X-750 Inconel alloy using two coated carbide inserts. This alloy is one of the most demanding advanced engineering materials due to its superior quality. Moreover, the comparative process benefit analysis of machinability aspect using coated carbide inserts are reported few. To collect the experimental data, the L16 experimental design plan is used to perform the experiment for a machining length of 40 mm. Four level of cutting speed (70,120,170,220 m/min), feed rate (0.1, 0.15, 0.2, 0.25 mm/rev) and cutting depth (0.3, 0.4, 0.5, 0.6 mm) were the cutting/machining parameters used. Cutting forces, surface roughness, flank and crater wear are considered as target functions. With application of response surface, coupled with desirability analysis, the optimal levels of combination are determined. With determined optimal levels, tool life study has been carried out to compare the effectiveness of cutting inserts.

Application of TOPSIS with Taguchi Method for Multi-attribute Optimization of Machining Parameters in EDM

  • Balaji Institute Of Technological Sci - Vikram Reddy Vaddi
  • JNTUH College of Engineering Manthani - Sridhar Reddy Ch
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  • Technical Paper
  • 2018-28-0033
Published 2018-07-09 by SAE International in United States
The present work focused on application of TOPSIS along with Taguchi method to optimize machining parameters in Electrical Discharge Machining (EDM) of Titanium alloy (Ti-6Al-4V) considering it as multi-attribute problem. The L9 orthogonal array of Taguchi method is used to conduct experiments. During experimentation Titanium alloy (Ti-6Al-4V) is chosen as a work material and electrolyte copper is selected as a tool electrode. Whereas peak current, pulse on time and pulse off time are chosen as machining parameters. TOPSIS method is applied to determine the optimal combination of machining parameters to yield maximum material removal rate (MRR), minimum tool wear rate (TWR) and surface roughness (SR) simultaneously. Confirmation experiments have been done at optimal parametric setting, then results are compared with predicted values and it was found that percentage error is less than 5.

Experiences Tuning an Augmented Power Unit Sound System for Both Interior and Exterior of an Electric Car

  • Ricardo UK, Ltd. - Matthew Maunder
Published 2018-06-13 by SAE International in United States

A system for realistic augmentation of power unit sound has been applied to an electric car. Augmented interior sound has been shown to be a powerful enabler for the acceptance and appeal of electric cars. In some territories augmented exterior sound is a legal requirement, to provide a safe urban environment particularly for vision-impaired pedestrians.


A Steady-State Based Investigation of Automotive Turbocharger Compressor Noise

  • Volvo Car Group, KTH - Asuka Gabriele Pietroniro
  • KTH Royal Institute of Technology - Mihai Mihaescu, Mats Abom
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Published 2018-06-13 by SAE International in United States

The challenging problem of noise generation and propagation in automotive turbocharging systems is of real interest from both scientific and practical points of view. Robust and fast steady-state fluid flow calculations, complemented by acoustic analogies can represent valuable tools to be used for a quick assessment of the problem during e.g. design phase, and a starting point for more in-depth future unsteady calculations.


On-Highway Equipment Control and Communication Network

  • Ground Vehicle Standard
  • J1939/1_201806
  • Current
Published 2018-06-12 by SAE International in United States

SAE J1939-1 On-Highway Equipment Control and Communication Network specifies the minimum set of SAE J1939 documents that define the Truck and Bus Control and Communications Vehicle Network as it applies to on-highway equipment. Vehicles covered include all on-highway straight trucks and combination vehicles. A combination vehicle consists of one towing vehicle (tractor) and one or more towed vehicles (trailers and dollies). Dolly axles within the road train are considered to be towed vehicles.


Game-Based Training Environment

  • Magazine Article
  • TBMG-29084
Published 2018-06-01 by Tech Briefs Media Group in United States

Charles River Analytics Cambridge, MA 617-491-3474


Ground-Based System Guides UAVs to Avoid Collisions

  • Magazine Article
  • TBMG-29047
Published 2018-06-01 by Tech Briefs Media Group in United States

The Federal Aviation Administration (FAA) averages more than 100 reports a month of interactions between unmanned aircraft systems (UAS) and commercial or private planes. For UAS to fly in civil airspace, they must be able to see, avoid, and remain “well clear” of other aircraft. With no pilot onboard to spot approaching aircraft, another sense-and-avoid (SAA) technique is required.


Using Social Network Analysis to Quantify Interoperability and Versatility in the U.S. Air Force Network of Systems

  • Stevens Institute of Technology - James Enos, Roshanak Nilchiani
Published 2018-05-10 by SAE International in United States

The Department of Defense (DoD) faces a similar challenge to the broader aerospace community in that they must integrate and operate a range of systems developed independently over a long period. It has proved difficult for the DoD to manage this network of systems and they must explore other options for analyzing and managing their systems. This paper explores the application of social network analysis tools and metrics to a network of aerospace systems within the U.S. Air Force. The structure of the network includes over one hundred U.S. Air Force systems including, aircraft, unmanned aerial vehicles, munitions, satellites, and command and control systems. The paper describes two separate networks based on direct connections and shared activities between these systems. For each of these networks measures of centrality, degree, closeness, betweenness, and eigenvector, quantify both the interoperability and versatility of the U.S. Air Force systems. These metrics appear to provide valuable insight into the network of systems and the results of the analysis align with general perceptions of the most interoperable and versatile DoD systems. In the interoperability network, the GPS III system, that provides information to nearly every other DoD system, ranked highest among the Air Force Systems. Also, in the versatility network, the A-10 and B-52, very versatile aircraft, scored very well based on the social network analysis metrics. Overall, social network analysis tools and metrics have the potential to provide systems engineers with valuable insights into the analysis, management, and design of systems. Although the initial results appear to be promising, future work should focus on validating the approach of applying social network analysis metrics to networks of systems and expand the work beyond the DoD realm to include other networks of systems.


Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys

  • The University of Alabama - J.F.C. Moraes, J.B. Jordon
  • Xuming Su
  • Show More
  • Journal Article
  • 05-11-02-0015
Published 2018-05-08 by SAE International in United States

In this work, the complex relationship between deformation history and residual stresses in a magnesium-to-aluminum self-pierce riveted (SPR) joint is elucidated using numerical and experimental approaches. Non-linear finite element (FE) simulations incorporating strain rate and temperature effects were performed to model the deformation in the SPR process. In order to accurately capture the deformation, a stress triaxiality-based damage material model was employed to capture the sheet piercing from the rivet. Strong visual comparison between the physical cross-section of the SPR joint and the simulation was achieved. To aid in understanding of the role of deformation in the riveting process and to validate the modeling approach, several experimental measurements were conducted. To quantify the plastic deformation from the piercing of the rivet, micro hardness mapping was performed on a cross-section of the SPR joint. The FE model showed very strong correlation to the experimental hardness mapping results suggesting the nonlinear model captured the plastic deformation with high accuracy. To measure the elastic residual stresses in the SPR joint, neutron and x-ray diffraction mapping techniques were conducted and in general, the FE model correlated well to the trends and magnitudes of the elastic stresses. While some error occurred in between the model and the neutron and x-ray diffraction results, the numerical approach developed in this study shows potential as a tool for understanding SPR behavior as well as optimizing the process parameters.