A study on kerf and material removal rate in wire electricaldischarge machining of Ti-6Al-4V: multi-objectives optimization

Abstract

This paper presents an investigation on the effect and optimization of machining parameters on the kerf (cutting width) and material removal rate (MRR) of titanium alloy (TI-6AL-4V) using wire electrical discharge machining WEDM with a brass wire diameter of 0.5mm. The experimental studies were conducted under varyingpulse-off time, peak current, wire feed and wire tension. The settings of machining parameters were determined by using Taguchi experimental design method. The multiple performance characteristics based on the statisticalbased analysis of variance (ANOVA) and grey relational analysis (GRA) was attempted. Analysis of variance was used to study the significance of process parameters on grey relational grade (GRG) which showed the most significant factor. The GRG obtained from the GRA was used to optimize the WEDM process. The optimum process parameters are determined by the GRG as the overall performance index. To validate the findings, confirmation experiment had been carried out at the optimal set of parameters, and the predicted results were found to be in good agreements with experimental findings. Improved machining performance in the WEDM process has been achieved by using this approach.

Integration of Fuzzy AHP and Fuzzy TOPSIS Methods for Wire Electric Discharge Machining of Titanium (Ti6Al4V) Alloy Using RSM

“…T off is most contributing factor (41.73%) on MRR followed by T on and current. Saedon et al [ 30 ] also reported T off as the most significant factor (58%) while investigating WEDM machining on Ti-6Al-4V alloy. The R 2 value of 98.29% indicates that 98.29% of the variation of MRR can be explained by the empirical model and only 1.71% of total variation cannot be described by the developed model.…”

“…This further increases the MRR by a large amount. Saedon et al [ 30 ] attributed increasing MRR with increasing T on and current to the reduced dynamic shear strength of Ti alloy due to higher thermal influence in the machining region. The outcome of T off on MRR shows a decreasing trend with a rise in T off because of reduced spark ejection time and less MRR [ 9 , 54 ].…”

“…To exhibit the viability for industrial applications, a scientific approach consisting of RSM and HTS algorithm was planned and prepared for optimization. Saedon et al [ 30 ] studied optimization of kerf and MRR during cutting of titanium (Ti6Al4V) alloy using WEDM. The experiments were performed with varying peak current, T off , wire tension, and wire feed.…”

Upper Bound Finite Element Limit Analysis of Pullout Characteristics of Normal-Stressed Circular Anchor Plate

“…The sensitivity of the dependent variable to the factor is determined by the variance associated with the factor. Since the method of analysis of variance has been widely used in various fields, such as fitting the expression of material strength and material composition in the material field [25,26], this paper employs the analysis of variance method to quantify the influence of various parameters on the pullout factor of the anchor plate for c > 0 kPa and φ > 0 °.…”

“…It is a concern that the derivation of theoretical formula of the pullout factor expression is too difficult to be described in previous researches. However, the method of fitting the expression of material strength and material composition in the material field [25,26] shows that the data analysis methods can determine the effect of related factors and the form of expression when reliable data is available.…”