Towards zero-defect manufacturing with a combined online - offline fuzzy-nets approach in wire electrical discharge machining

Ahmed Bufardi, Olcay Akten, Muhammad Arif, Paul Xirouchakis, Roberto Perez

Research output: Contribution to journalArticle

Abstract

Current practice of wire electrical discharge machining (W-EDM) is not defect free and still a number of parts produced by WEDM processes are rejected due to different defects. The main defects related to surface quality of W-EDMed parts include occurrence of surface lines, surface roughness, and recast layer (also called white layer). In this paper we characterize the different types of defects and for each of them we propose the appropriate approach to handle it. To achieve zero-defect manufacturing in W-EDM, one can intervene before starting machining operations through selecting the best combination of values of process parameters to meet required levels of performance for part quality characteristics, and during machining operations through monitoring machining conditions to predict any potential defect and take appropriate actions to prevent the effective occurrence of defects if and when predicted. This paper addresses both issues and a combined online - offline fuzzy-nets approach is proposed. It is noteworthy, that for the first time in the published literature, an approach is presented to prevent the occurrence of surface lines in W-EDM; this is accomplished by our experimentally validated system by: (i) high frequency sensing and processing of the current signal in the discharge zone; (ii) the development of a new algorithm for the detection and calculation of the duration of a series of consecutive short circuits; and (iii) the proactive adjustment of the pulse–off time through an adaptive fuzzy nets system.
LanguageEnglish
Article number42
Pages401-409
Number of pages9
JournalWSEAS Transactions on Environment and Development
Volume13
Publication statusPublished - 2017

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Electric discharge machining
defect
manufacturing
Wire
Defects
Machining
monitoring
performance
Values
surface roughness
Short circuit currents
Surface properties
Surface roughness
Monitoring
Processing
time
literature

Keywords

  • critical process variable
  • part quality characteristic
  • vital process parameter
  • WEDM

Cite this

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title = "Towards zero-defect manufacturing with a combined online - offline fuzzy-nets approach in wire electrical discharge machining",
abstract = "Current practice of wire electrical discharge machining (W-EDM) is not defect free and still a number of parts produced by WEDM processes are rejected due to different defects. The main defects related to surface quality of W-EDMed parts include occurrence of surface lines, surface roughness, and recast layer (also called white layer). In this paper we characterize the different types of defects and for each of them we propose the appropriate approach to handle it. To achieve zero-defect manufacturing in W-EDM, one can intervene before starting machining operations through selecting the best combination of values of process parameters to meet required levels of performance for part quality characteristics, and during machining operations through monitoring machining conditions to predict any potential defect and take appropriate actions to prevent the effective occurrence of defects if and when predicted. This paper addresses both issues and a combined online - offline fuzzy-nets approach is proposed. It is noteworthy, that for the first time in the published literature, an approach is presented to prevent the occurrence of surface lines in W-EDM; this is accomplished by our experimentally validated system by: (i) high frequency sensing and processing of the current signal in the discharge zone; (ii) the development of a new algorithm for the detection and calculation of the duration of a series of consecutive short circuits; and (iii) the proactive adjustment of the pulse–off time through an adaptive fuzzy nets system.",
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author = "Ahmed Bufardi and Olcay Akten and Muhammad Arif and Paul Xirouchakis and Roberto Perez",
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Towards zero-defect manufacturing with a combined online - offline fuzzy-nets approach in wire electrical discharge machining. / Bufardi, Ahmed; Akten, Olcay; Arif, Muhammad; Xirouchakis, Paul; Perez, Roberto.

In: WSEAS Transactions on Environment and Development, Vol. 13, 42, 2017, p. 401-409.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Towards zero-defect manufacturing with a combined online - offline fuzzy-nets approach in wire electrical discharge machining

AU - Bufardi, Ahmed

AU - Akten, Olcay

AU - Arif, Muhammad

AU - Xirouchakis, Paul

AU - Perez, Roberto

N1 - © 2017 World Scientific and Engineering Academy and Society (WSEAS). Bufardi, A, Akten, O, Arif, M, Xirouchakis, P & Perez, R 2017, 'Towards zero-defect manufacturing with a combined online - offline fuzzy-nets approach in wire electrical discharge machining' WSEAS Transactions on Environment and Development, vol 13, pp. 401-409. The final publication is available at http://wseas.org/wseas/cms.action?id=15004.

PY - 2017

Y1 - 2017

N2 - Current practice of wire electrical discharge machining (W-EDM) is not defect free and still a number of parts produced by WEDM processes are rejected due to different defects. The main defects related to surface quality of W-EDMed parts include occurrence of surface lines, surface roughness, and recast layer (also called white layer). In this paper we characterize the different types of defects and for each of them we propose the appropriate approach to handle it. To achieve zero-defect manufacturing in W-EDM, one can intervene before starting machining operations through selecting the best combination of values of process parameters to meet required levels of performance for part quality characteristics, and during machining operations through monitoring machining conditions to predict any potential defect and take appropriate actions to prevent the effective occurrence of defects if and when predicted. This paper addresses both issues and a combined online - offline fuzzy-nets approach is proposed. It is noteworthy, that for the first time in the published literature, an approach is presented to prevent the occurrence of surface lines in W-EDM; this is accomplished by our experimentally validated system by: (i) high frequency sensing and processing of the current signal in the discharge zone; (ii) the development of a new algorithm for the detection and calculation of the duration of a series of consecutive short circuits; and (iii) the proactive adjustment of the pulse–off time through an adaptive fuzzy nets system.

AB - Current practice of wire electrical discharge machining (W-EDM) is not defect free and still a number of parts produced by WEDM processes are rejected due to different defects. The main defects related to surface quality of W-EDMed parts include occurrence of surface lines, surface roughness, and recast layer (also called white layer). In this paper we characterize the different types of defects and for each of them we propose the appropriate approach to handle it. To achieve zero-defect manufacturing in W-EDM, one can intervene before starting machining operations through selecting the best combination of values of process parameters to meet required levels of performance for part quality characteristics, and during machining operations through monitoring machining conditions to predict any potential defect and take appropriate actions to prevent the effective occurrence of defects if and when predicted. This paper addresses both issues and a combined online - offline fuzzy-nets approach is proposed. It is noteworthy, that for the first time in the published literature, an approach is presented to prevent the occurrence of surface lines in W-EDM; this is accomplished by our experimentally validated system by: (i) high frequency sensing and processing of the current signal in the discharge zone; (ii) the development of a new algorithm for the detection and calculation of the duration of a series of consecutive short circuits; and (iii) the proactive adjustment of the pulse–off time through an adaptive fuzzy nets system.

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JO - WSEAS Transactions on Environment and Development

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JF - WSEAS Transactions on Environment and Development

SN - 1790-5079

M1 - 42

ER -