Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm

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Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm

Rakesh Chaudhari , Jay J. Vora , S. S. Mani Prabu , I. A. Palani , Vivek K. Patel , D. M. Parikh

Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (1) : 64 -80.

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Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (1) : 64 -80. DOI: 10.1007/s40436-019-00267-0

Article

Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm

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¹ Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, 382007, Raisan, Gandhinagar, India

² Metallurgy Engineering and Materials Science, Indian Institute of Technology Indore, 453552, Indore, India

³ Discipline of Mechanical Engineering, Indian Institute of Technology Indore, 453552, Indore, India

⁴ Department of Industrial Engineering, School of Technology, Pandit Deendayal Petroleum University, 382007, Raisan, Gandhinagar, India

^b vorajaykumar@gmail.com

Mr. Rakesh Chaudhari is presently working as a lecturer in mechanical engineering department, PDPU, Gandhinagar since July 2014. He completed his bachelor degree in Mechanical Engineering from Government College of engineering, Jalgaon in 2012. He completed his M.Tech in Mechanical Engineering from SVNIT, Surat in June 2014. He has completed his dissertation from IIT, Bombay. During his M.Tech dissertation at IIT Bombay, he has worked with National centre for aerospace innovation and research. He is currently pursuing his Ph.D. research at PDPU in the field of Experimental investigation of electrical discharge machining of Shape memory alloys. He has attended several national and international conferences. He has received an excellent paper award in International conference of Science, Engineering and Technology at Singapore, May 2017. His key research interest revolves around experimental investigations of non-conventional machining techniques for futuristic advanced alloys.

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Dr. Jay J. Vora is working as an Assistant Professor in mechanical engineering department of PDPU. He is the recipient of the prestigious Visiting Scientist Award from Indian National Science academy (INSA). He completed his Ph.D. in Advanced welding technology at Pandit Deendayal Petroleum University (PDPU). His Ph.D. research project was pivoted to A-TIG welding of RAFM steels. He completed his masters in welding technology course from MSU, Baroda in 2012 and being a sponsored candidate thereupon worked with L&T Heavy engineering division. He has also worked as visiting faculty and research scholar at Lamar University, Texas, USA. He has several international journal publications and attended several national and international conferences many of which were supported by the SERB, Govt. Of India. He is also working on multiple projects funded by BRNS, ORSP, etc. He is also reviewer for many international peer-reviewed journals/books. In addition to this, recently he has created an online YouTube channel named “Researchers Online” wherein he has uploaded several videos covering basic aspects of research, particularly for young researchers and students. His key research interest revolves around development of advanced welding techniques such as A-TIG, FSW, FSSW, LBW etc. particularly for Low alloy steels, dissimilar combinations as well as different ferrous and non-ferrous steels.

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Mr. S. S. Mani Prabu is currently working as a Ph.D. student at Indian Institute of Technology Indore. He mainly works on solid state joining and additive manufacturing of NiTi shape memory alloys. His areas of interest includes the development of shape memory alloys-bulk and thin films, actuation control of shape memory alloys, smart composites and corrosion engineering.

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Dr. I. A. Palani is a Associate Professor and serving as the head of Discipline of Mechanical Engineering, IIT Indore. He received his Ph.D. from IIT Madras, India. Then, he worked as a post-doctoral research scientist at Graduate school of Information Science and Electrical Engineering, Kyushu University, Japan. He has authored book chapters on “ZnO Nanocrystals and allied Materials”. His area of interest includes laser based materials processing, shape memory alloys, opto-mechatronics, piezoelectricity and nano structures for functional device.

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Dr. Vivek K. Patel is working as an Assistant Professor in mechanical engineering department of PDPU. Dr. Vivek Patel has obtained his Ph.D. from S.V. National Institute of Technology, Surat with the specialization in advanced optimization algorithms and its applications. He has developed an optimization technique called “Heat Transfer Search (HTS)”. He has also proposed various hybrid and modified optimization techniques. He has published many reputed International Journal papers in Elsevier, Springer, Taylor and Francis etc.

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Dr. D. M. Parikh is working as an Adjunct Professor in Industrial engineering department of PDPU. He completed his Ph.D. in Financial Intermediations for Industrial growth post liberalization, Singhania University in 2013. He completed his masters in Industrial management from IIT, Kharagpur in 1983. He has several international journal publications and attended several national and international conferences. He is having 35 years of experience across training, academic & practicing in the field of industrial engineering; project financing & entrepreneurship. His key research interest revolves around Production & Operation Management, Finance & Management Accounting, domain skill for promoting & facilitating entrepreneurship in institutes & university and non-conventional machining techniques.

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Abstract

Machining of shape memory alloys (SMAs) without losing the shape memory effect could immensely extend their applications. Herein, the wire electric discharge machining process was used to machine NiTi—a shape memory alloy. The experimental methodology was designed using a Box-Behnken design approach of the response surface methodology. The effects of input variables including pulse on time, pulse off time, and current were investigated on the material removal rate, surface roughness, and microhardness. ANOVA tests were performed to check the robustness of the generated empirical models. Optimization of the process parameters was performed using a newly formulated, highly efficient heat transfer search algorithm. Validation tests were conducted and extended for analyzing the retention of the shape memory effect of the machined surface by differential scanning calorimetry. In addition, 2D and 3D Pareto curves were generated that indicated the trade-offs between the selected output variables during the simultaneous output variables using the multi-objective heat transfer search algorithm. The optimization route yielded encouraging results. Single objective optimization yielded a maximum material removal rate of 1.49 mm³/s, maximum microhardness 462.52 HVN, and minimum surface roughness 0.11 µm. The Pareto curves showed conflicting effects during the wire electric discharge machining of the shape memory alloy and presented a set of optimal non-dominant solutions. The shape memory alloy machined using the optimized process parameters even indicated a shape memory effect similar to that of the starting base material.

Keywords

Shape memory alloy (SMA) / Nitinol / Wire electrical discharge machining (WEDM) / Heat transfer search algorithm / Differential scanning calorimetry (DSC) test / Shape memory effect

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Rakesh Chaudhari, Jay J. Vora, S. S. Mani Prabu, I. A. Palani, Vivek K. Patel, D. M. Parikh. Pareto optimization of WEDM process parameters for machining a NiTi shape memory alloy using a combined approach of RSM and heat transfer search algorithm. Advances in Manufacturing, 2021, 9(1): 64-80 DOI:10.1007/s40436-019-00267-0

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