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| 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. Present experimental investigation aims to determine suitable input process/machining parameters, e.g. pulse on time (T ON), 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 Taguchi L9 Orthogonal Array (OA) design approach has been used for the experimental purpose to enhance the process effiency. Similarly, a simple and popular multiresponse optimization approach, namely Grey Relational Analysis (GRA), is used to optimize five performance characteristics(output responses) simultaneously. The optimum process variables obtained are: TON of 110 μs, TOFFof 40 μs, IP of 10 A, and WF of 6 mm/min. These optimum process variables are validated with confirmatory experiment. The relative impact of input variables is determined using the Analysis of Variance (ANOVA) technique. Finally, correlations between individual outputs with different input parameters are established. This work will be helpful for industry personnel to use this machining process in a techno-economic 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: |
