Startseite Genetic evolutionary approach for surface roughness prediction of laser sintered Ti–6Al–4V in EDM
Artikel
Lizenziert
Nicht lizenziert Erfordert eine Authentifizierung

Genetic evolutionary approach for surface roughness prediction of laser sintered Ti–6Al–4V in EDM

  • Mehmet Mahir Sofu , Fatih Taylan und Tolgahan Ermergen ORCID logo EMAIL logo
Veröffentlicht/Copyright: 17. Dezember 2020

Abstract

Additive Manufacturing (AM) methods, in the field of production, are increasing rapidly. In particular, the use of Ti alloys has an important role in AM methods. The major disadvantage of AM methods is low surface quality of the manufactured parts. Therefore, parts produced using AM methods need subsequent surface treatment. Electro Discharge Machining (EDM) is one of the nontraditional machining methods, which can be used to improve the surface quality with appropriate parameters. In this study, EDM was investigated to improve the surface quality of sintered Ti–6Al–4V alloy by using 160 different finish parameters. It was observed that Current (I) has a notable effect on surface roughness showing that best surface quality is achieved with low current values, which is under Ra = 2 µm. To estimate the final result of EDM, roughness values obtained from the experiments were modeled by using the Genetic Expression Programming (GEP), and a mathematical relationship between the obtained roughness values and EDM parameters was proposed. As a result of 830,900 iterations, GEP model created can estimate the final surface roughness of the parts with 84% accuracy.


Corresponding author: Tolgahan Ermergen, Department of Mechanical Engineering, Faculty of Technology, Isparta University of Applied Sciences, Isparta, Turkey, E-mail:

  1. Author contribution: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.

  2. Research funding: None declared.

  3. Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

References

[1] J. D. Destefani, “Introduction to titanium and titanium alloys,” in ASM Handbook: Properties and Selection: Nonferrous Alloys and Special-Purpose Materials, vol. 2, ASM Handbook Committee, 1990.10.31399/asm.hb.v02.a0001080Suche in Google Scholar

[2] C. H. Che-Haron and A. Jawaid, “The effect of machining on surface integrity of titanium alloy Ti-6% Al-4%V,” J. Mater. Process. Technol., vol. 160, no. 2(1), pp. 188–192, 2005, https://doi.org/10.1016/j.jmatprotec.2004.08.012.Suche in Google Scholar

[3] B. Gugulothu, D. H. Rao, and G. K. M. Rao, “Optimization of Edm process parameters and graphite powder concentration on electrical discharge machining of Ti-6Al-4V alloy using Taguchi method,” Int. J. Adv. Prod. Mech. Eng., vol. 1, no. 5, pp. 31–44, 2015.Suche in Google Scholar

[4] B. Baufeld, O. V. der Biest, and R. Gault, “Additive manufacturing of Ti–6Al–4V components by shaped metal deposition: microstructure and mechanical properties,” Mater. Des., vol. 31, no. 1, pp. 106–111, 2009, https://doi.org/10.1016/j.matdes.2009.11.032.Suche in Google Scholar

[5] L. M. Galantucci, F. Lavecchia, and G. Percoco, “Experimental study aiming to enhance the surface finish of fused deposition modeled parts,” CIRP Ann. – Manuf. Technol., vol. 58, no. 1, pp. 189–192, 2009, https://doi.org/10.1016/j.cirp.2009.03.071.Suche in Google Scholar

[6] O. Çolak, C. Kurbanoğlu, and M. C. Kayacan, “Milling surface roughness prediction using evolutionary programming methods,” Mater. Des., vol. 28, no. 2, pp. 657–666, 2007, https://doi.org/10.1016/j.matdes.2005.07.004.Suche in Google Scholar

[7] M. Brezocnik, M. Kovavic, and M. Ficko, “Prediction of surface roughness with genetic programming,” J. Mater. Process., vols 157–158, pp. 28–36, 2004, https://doi.org/10.1016/j.jmatprotec.2004.09.004.Suche in Google Scholar

[8] C. Göloğlu and Y. Arslan, “Zigzag machining surface roughness modelling using evolutionary approach,” J. Intell. Manuf., vol. 20, no. 2, pp. 203–210, 2009, https://doi.org/10.1007/s10845-008-0222-1.Suche in Google Scholar

[9] M. Sekulic, V. Pejic, M. Brezocnik, M. Gostimirovic, and M. Hadzistevic, “Prediction of surface roughness in the ball‐end milling process using response surface methodology, genetic algorithms, and grey wolf optimizer algorithm,” Adv. Prod. Eng. Manag., vol. 13, pp. 18–30, 2018, https://doi.org/10.14743/apem2018.1.270.Suche in Google Scholar

[10] Ö. Salman and M. C. Kayacan, “Evolutionary programming method for modeling the EDM parameters for roughness,” J. Mater. Process. Technol., vol. 200, nos. 1–3, pp. 347–355, 2008, https://doi.org/10.1016/j.jmatprotec.2007.09.022.Suche in Google Scholar

[11] R. Jha, F. Pettersson, G. S. Dulikravich, H. Saxen, and N. Chakraborti, “Evolutionary design of nickel-based superalloys using data-driven genetic algorithms and related strategies,” Mater. Manuf. Process., vol. 30, no. 4, pp. 488–510, 2015, https://doi.org/10.1080/10426914.2014.984203.Suche in Google Scholar

[12] H.–J. Park, J.–S. Lim, and J. M. Kang, “Optimization of gas production systems using fuzzy nonlinear programming and co-evolutionary genetic algorithm,” Energy Sources, Part A Recovery, Util. Environ. Eff., vol. 30, no. 9, pp. 818–825, 2008, https://doi.org/10.1080/15567030600817852.Suche in Google Scholar

[13] G. N. Levy, R. Schindel, and J. P. Kruth, “Rapid manufacturing and rapid tooling with layer manufacturing (LM) technologies, state of the art and future perspectives,” CIRP Ann. – Manuf. Technol., vol. 52, no. 2, pp. 589–609, 2003, https://doi.org/10.1016/S0007-8506(07)60206-6.Suche in Google Scholar

[14] M. W. Khaing, J. Y. H. Fuh, and L. Lu, “Direct metal laser sintering for rapid tooling: processing and characterisation of EOS parts,” J. Mater. Process. Technol., vol. 113, nos 1–3, pp. 269–272, 2001, https://doi.org/10.1016/S0924-0136(01)00584-2.Suche in Google Scholar

[15] N.L Gideon, R Schindel, and J.P Kruth, “Rapid manufacturing and rapid tooling with layer manufacturing (LM) technologies, state of the art and future perspectives,” CIRP Ann., vol. 52, no. 2, pp. 589–609, 2003, https://doi.org/10.1016/S0007-8506(07)60206-6.Suche in Google Scholar

[16] D. Shi and I. Gibson, “Surface finishing of selective laser sintering parts with robot,” in Proceedings 9th Solid Free Fabrication Symposium, Austin, Texas, 1998. Available at: http://utw10945.utweb.utexas.edu/Manuscripts/1998/1998-03-Shi.pdf [accessed: Sep. 7, 2020].Suche in Google Scholar

[17] A. Fatemi, R. Molaei, S. Sharifimehr, N. Shamsaei, and N. Phan, “Torsional fatigue behavior of wrought and additive manufactured Ti-6Al-4V by powder bed fusion including surface finish effect,” Int. J. Fatig., vol. 99, no. 1, pp. 187–201, 2017, https://doi.org/10.1016/j.ijfatigue.2017.03.002.Suche in Google Scholar

[18] J. A. Slotwinski and E. J. Garboczi, “Porosity of additive manufacturing parts for process monitoring,” J. Res. Nat. Inst. Stand. Technol., vol. 119, pp. 494–528, 2014, https://doi.org/10.1063/1.4864957.Suche in Google Scholar

[19] S. Rossi, F. Deflorian, and F. Venturini, “Improvement of surface finishing and corrosion resistance of prototypes produced by direct metal laser sintering,” J. Mater. Process. Technol., vol. 148, no. 3, pp. 301–309, 2004, https://doi.org/10.1016/j.jmatprotec.2003.02.001.Suche in Google Scholar

[20] M. Shellabear and O Nyrhilä, “DMLS-development history and state of the art,” in Proceedings of the 4th LANE, Bamberg, Meisenbach, 2004.Suche in Google Scholar

[21] S. T. Chiang, D. I. Liu, A. C. Lee, and W. H. Chieng, “Adaptive control optimization in end milling using neural networks,” Int. J. Mach. Tool Manuf., vol. 35, no. 4, pp. 637–660, 1995, https://doi.org/10.1016/0890-6955(94)P4355-X.Suche in Google Scholar

[22] S. Liu, S. Jin, X. Zhang, K. Chen, L. Wang, and H. Zhao, “Optimization of 3D surface roughness induced by milling operation for adhesive-sealing,” Procedia CIRP, vol. 71, pp. 279–284, 2018, https://doi.org/10.1016/j.procir.2018.05.011.Suche in Google Scholar

[23] C. Formanoir, S. Michotte, O. Rigo, L. Germain, and S. Godet, “Electron beam melted Ti-6Al-4V: microstructure, texture and mechanical behavior of the as-built and heat-treated material,” Mater. Sci. Eng., vol. 652, pp. 105–119, 2016, https://doi.org/10.1016/j.msea.2015.11.052.Suche in Google Scholar

[24] S. Liu and Y. C. Shin, “Additive manufacturing of Ti6Al4V alloy: A review,” Mater. Des., vol. 164, pp. 1–23, 2019, https://doi.org/10.1016/j.matdes.2018.107552.Suche in Google Scholar

[25] Caceres, J. T. “A framework for miniaturized mechanical characterization of tensile, creep, and fatigue properties of SLM alloys.” Electron. Theses Diss. 2018. Available at: https://stars.library.ucf.edu/cgi/viewcontent.cgi?article=6833&context=etd [accessed Sep. 07, 2020].Suche in Google Scholar

[26] D. Greitemeier, C. Dalle Donne, F. Syassen, J. Eufinger, and T. Melz, “Effect of surface roughness on fatigue performance of additive manufactured Ti–6Al–4V,” Mater. Sci. Technol., vol. 32, no. 7, pp. 629–634, 2016. https://doi.org/10.1179/1743284715Y.0000000053.Suche in Google Scholar

[27] S. Begoc, S. Palerm, R. Salapete, M. Theron, and J. Dehouve, “Additive manufacturing at French space agency with industry partnership,” Adv. 3D Print. Addit. Manuf. Technol., pp. 111–120, 2017.10.1007/978-981-10-0812-2_10Suche in Google Scholar

[28] J. Vaithilingam, R. D. Goodridge, R. J. M. Hague, S. D. R. Christie, and S. Edmondson, “The effect of laser remelting on the surface chemistry of Ti6Al4V components fabricated by selective laser melting,” J. Mater. Process. Technol., vol. 232, pp. 1–8, 2016, https://doi.org/10.1016/j.jmatprotec.2016.01.022.Suche in Google Scholar

[29] S. Bagehorn, J. Wehr, and H. J. Maier, “Application of mechanical surface finishing processes for roughness reduction and fatigue improvement of additively manufactured Ti-6Al-4V parts,” Int. J. Fatig., vol. 102, pp. 135–142, 2017, https://doi.org/10.1016/j.ijfatigue.2017.05.008.Suche in Google Scholar

[30] A. Boschetto, L. Bottini, and F. Veniali, “Surface roughness and radiusing of Ti6Al4V selective laser melting-manufactured parts conditioned by barrel finishing,” Int. J. Adv. Manuf. Technol., vol. 94, no. 4, pp. 2773–2790, 2018, https://doi.org/10.1007/s00170-017-1059-6.Suche in Google Scholar

[31] M. Seifi, D. Christiansen, J. Beuth, O. Harrysson, and J. J. Lewandowski, “Process mapping, fracture and fatigue behavior of Ti-6Al-4V produced by Ebm additive manufacturing,” in Proceedings of the 13th World Conference on Titanium, vol. 232, 2016, pp. 1373–1377, https://doi.org/10.1002/9781119296126.ch232.Suche in Google Scholar

[32] H. Galarraga, D. A. Lados, R. R. Dehoff, M. M. Kirka, and P. Nandwana, “Effects of the microstructure and porosity on properties of Ti-6Al-4V ELI alloy fabricated by electron beam melting (EBM),” Addit. Manuf., vol. 10, pp. 47–57, 2016, https://doi.org/10.1016/j.addma.2016.02.003.Suche in Google Scholar

[33] A. Hasçalık and U. Çaydaş, “A comparative study of surface integrity of Ti-6Al-4V alloy machined by EDM and AECG,” J. Mater. Process. Technol., vol. 190, nos 1–3, pp. 173–180, 2007b, https://doi.org/10.1016/j.jmatprotec.2007.02.048.Suche in Google Scholar

[34] A. Hasçalık and U. Çaydaş, “Electrical discharge machining of titanium alloy (Ti-6Al-4V),” Appl. Surf. Sci., vol. 253, no. 22, pp. 9007–9016, 2007a, https://doi.org/10.1016/j.apsusc.2007.05.031.Suche in Google Scholar

[35] B. K. Baroi, S. Kar, and P. K. Patowari, “Electric discharge machining of titanium grade 2 alloy and its parametric study,” Mater. Today: Proc., vol. 5, no. 2, pp. 5004–5011, 2018, https://doi.org/10.1016/j.matpr.2017.12.078.Suche in Google Scholar

[36] X. Wang, Z. Liu, R. Xue, Z. Tian, and Y. Huang, “Research on the influence of dielectric characteristics on the EDM of titanium alloy,” Int. J. Adv. Manuf. Technol., vol. 72, pp. 979–987, 2014, https://doi.org/10.1007/s00170-014-5716-8.Suche in Google Scholar

[37] M. B. Ndaliman, A. A. Khan, and M. Y. Ali, “Surface modification of titanium alloy through electrical discharge machining (EDM),” Int. J. Mech. Mater. Eng., vol. 6, no. 3, pp. 380–384, 2011.Suche in Google Scholar

[38] J. S. Soni and G. Chakraverti, “Surface characteristics of titanium with rotary EDM,” Bull. Mater. Sci., vol. 16, no. 3, pp. 51–58, 1993, https://doi.org/10.1007/BF02745147.Suche in Google Scholar

[39] R. Kumar, S. Roy, P. Gunjan, A. Sahoo, D. D. Sarkar, and R. K. Das, “Analysis of MRR and surface roughness in machining Ti-6Al-4V ELI titanium alloy using EDM process,” Procedia Manuf., vol. 20, pp. 358–364, 2018, https://doi.org/10.1016/j.promfg.2018.02.052.Suche in Google Scholar

[40] Y. C. Lin, B. H. Yan, and Y. S. Chang, “Machining characteristics of titanium alloy (Ti–6Al–4V) using a combination process of EDM with USM,” J. Mater. Technol. Process., vol. 104, pp. 171–177, 2000, https://doi.org/10.1016/S0924-0136(00)00539-2.Suche in Google Scholar

[41] J. F. Liang, Y. S. Liao, J. Y. Kao, C. H. Huang, and C. Y. Hsu, “Study of the EDM performance to produce a stable process and surface modification,” Int. J. Adv. Manuf. Technol., vol. 95, pp. 1743–1750, 2018, https://doi.org/10.1007/s00170-017-1315-9.Suche in Google Scholar

[42] L. Praveen, P. G. Krishna, L. Venugopal, and N. E. C. Prasad, “Effects of pulse on and off time and electrode types on the material removal rate and tool wear rate of the Ti-6Al-4V Alloy using EDM machining with reverse polarity,” IOP Conf. Ser. Mater. Sci. Eng., pp. 330–337, 2018.10.1088/1757-899X/330/1/012083Suche in Google Scholar

[43] C. Sharma, S. Maheshwari, and P. S. Bharti, “Experimental investigation of inconel 718 during die-sinking electric discharge machining,” Int. J. Eng. Sci. Technol., vol. 2, no. 11, pp. 6464–6473, 2010.Suche in Google Scholar

[44] K. Umanath and D. Devika, “Optimization of electric discharge machining parameters on titanium alloy (Ti-6Al-4V) using Taguchi parametric design and genetic algorithm,” MATEC Web Conf., vol. 172, no. 6, 2018, https://doi.org/10.1051/matecconf/201817204007.Suche in Google Scholar

[45] A. K. Sahu and S. S. Mahapatra, “Optimization of electrical discharge machining of titanium alloy (Ti6Al4V) by grey relational analysis based firefly algorithm,” Addit. Manuf. Emerg. Mater., pp. 29–53, 2019.10.1007/978-3-319-91713-9_2Suche in Google Scholar

[46] C. Ferreira, “Gene expression programming: A new adaptive algorithm for solving problems,” Complex Syst., vol. 13, no. 2, pp. 87–129, 2001, https://doi.org/10.1007/978-1-4471-0123-9_54.Suche in Google Scholar

[47] P. G. Benardos and G. C. Vosniakos, “Predicting surface roughness in machining: A review,” Int. J. Mach. Tool Manuf., vol. 43, no. 8, pp. 833–844, 2003, https://doi.org/10.1016/S0890-6955(03)00059-2.Suche in Google Scholar

[48] L. Li, L. Gu, X. Xi, and W. Zhao, “Influence of flushing on performance of EDM with bunched electrode,” Int. J. Adv. Manuf. Technol., vol. 58, pp. 187–194, 2012, https://doi.org/10.1007/s00170-011-3357-8.Suche in Google Scholar

Received: 2020-09-23
Accepted: 2020-11-24
Published Online: 2020-12-17
Published in Print: 2021-03-26

© 2020 Walter de Gruyter GmbH, Berlin/Boston

Heruntergeladen am 2.12.2025 von https://www.degruyterbrill.com/document/doi/10.1515/zna-2020-0267/pdf
Button zum nach oben scrollen