Response Surface Modelling and Effective Application of Adaptive Neuro-Fuzzy Inference System to Analyze Surface Roughness of Al/Gr/Cp5 MMC Machined using WEDM

ABSTRACT

This paper presents an investigation of wire electrical discharge machining (WEDM) of new fabricated aluminium base composite with 5% graphite by weight, i.e., Al/Gr/Cp5. The new fabricated metal matrix composite (MMC) has a complete application in space, defence, automobile, and other concerned metal industries. In this work, adaptive neuro-fuzzy inference system (ANFIS) and the response surface method (RSM) were selected for the analysis and modelling purposes. ANFIS is a soft computing technique used in nonlinear data training. Taguchi’s L₂₇ plan was employed to conduct the experiments. The process parameters such as pulse-on time (PON), pulse-off time (POFF), a feed rate of wire (FRW) and the input current (IC) were selected for the experimentation. Based on the experimental findings, PON is identified as the most dominant parameter and the input current. WEDM performance was measured in terms of surface roughness (SR). For the optimised (minimum) surface roughness of 1.8625 microns, the best set of process parameters was PON (108 μs), POFF (52 μs), FRW (4 m/min) and the input current (12 Amp). ANFIS-predicted results were compared with the experimental results. An acceptable agreement is observed with the high value of the correlation coefficient (R² = 0.9624). The soft computing technique, like ANFIS-RSM, shows a good competency and reliability for the presented work.

KEYWORDS:

• Wire EDM
• Al/Gr/Cp5
• ANFIS
• RSM
• surface roughness

Acknowledgments

The authors would like to thank Kakade laser industries, Narhe, Pune, and the faculties of the Mechanical Engineering Department, All India Shri Shivaji Memorial Society’s College of Engineering, Pune, Maharashtra, India, for providing facilities and support for the presented work.

D ata a vailability s tatement (DAS)

The authors confirm that the data supporting the findings of this study are available within the article [and/or] its supplementary materials.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Mangesh Phate

Mangesh Phate completed Bachelors degree in Mechanical Engineering from Amravati University, Amravati  in 2002 & Masters of Technology degree in Production Engineering with First university rank and Gold Medals in 2005 from R.T.M. Nagpur University, Nagpur. He has completed PhD in Mechanical Engineering from R.T.M. Nagpur University, Nagpur in 2015. Now he is working as Associate Professor in Mechanical Engineering Department at  All India Shri Shivaji Memorial Society's, College of Engineering, Pune, Maharashtra, India-411001, since 2016. His area of interest is advanced manufacturing processes, ergonomics, Multi response optimization and design engineering.He has number of copyrights and books for the innovative process related to the NBA and research methodology.  He is permanent member of Indian society ISTE from 2003.He received Best teacher award (Rank 1) in 2019 from AISSM'S Pune.

Shraddha Toney

Shraddha Toney has obtained her Bachelor’s degree in Information Technology from Amravati university, Amravati in 2006 and Masters of Engineering in Computer Engineering from Savitribai Phule Pune University, Pune. She has about 14 years of teaching experience. Her area of interest includes soft computing techniques, cloud computing etc.She is currently working at Sinhgad Institute of Technology and Science , Pune, Maharashtra, India.

Vikas Phate

Vikas Phate has obtained his Bachelor’s in Electronics and Telecommunication Engineering from Amravati University, Amravati in 2004 and  Master’s in Electronics in 2009 from Dr. Babasaheb Ambedkar Marathwada University, Aurangabad and  PhD (QIP Scheme) from NIT, Tiruchirappalli, Tamilnadu in January 2021 , India. He is currently working at Government Polytechnic Murtizapur,Akola, Maharashtra, India. His research area is image processing, computer vision system, Statistic analysis etc.