|
| Abstract: |
| Wire-Electrical Discharge Machining (WEDM) process can create any complex contour in any conducting material, regardless of its strength or hardness, with higher accuracy. The aim of present experimental investigation is to determine suitable input process/machining parameters, e.g. pulse on time (TON), peak current (IP), wire feed rate (WF), and pulse off time (TOFF), for optimizing the process performances, namely cutting rate, kerf width, average roughness value of the machined surface, micro hardness, and surface crack density. Since four input parameters are considered in the present investigation, and each parameter is assumed to vary at three different levels (i.e. low, medium, high), the L9 Orthogonal Array (OA) design approach of Taguchi concept has been used for the experimental purpose to enhance the process economy. Similarly, a simple and popular multiresponse optimization approach, namely Grey Relational Analysis (GRA), is used to simultaneously optimize these five performance characteristics. The optimum process variables obtained are: 110μs of TON, 40μs of TOFF, 10A of IP and 6mm/min of WF. These optimum process variables are validated with confirmatory experiment. The relative impact of input variables is determined using Analysis of Variance (ANOVA) technique. Finally, correlations between individual output with different input parameters are established. This work will be helpful for industry personnel to use this machining process in a techno-economical way. |
| Key words: WEDM surface roughness surface crack density GRA ANOVA orthogonal array |
| DOI：10.11916/j.issn.1005-9113.2024055 |
| Clc Number:TG5 |
| Fund: |
