Multi-response Optimisation of Wire-EDM for SLMed AlSi10Mg using Taguchi-Grey Relational Theory

Abstract

The present research effort strives to optimise the multi-response during Wire Electrical Discharge Machining (Wire-EDM) of SLMed AlSi10Mg, applying Taguchi integrated Grey Relational Analysis (GRA). Selective Laser Melting (SLM) represents one of the best-known and most practicable Additive Manufacturing (AM) methods that have the prospective to serve as a replacement for many traditional production processes. Extremely intricate metallic support structures built up during SLM need more attention since they are too difficult to remove by hand. Therefore, post-processing adopting the Wire-EDM precision machining technique is performed in this study to assess the machinability of the SLMed AlSi10Mg as-built part. The multi-response optimisation used here seeks to achieve maximum material removal rate and lowest surface roughness while considering four important influencing elements (pulse On time, pulse Off time, servo voltage, and wire feed rate) at four distinct levels. Taguchi integrated Grey Relational Analysis (GRA) revealed that a pulse On time of 118 µs (Level 3), a pulse Off time of 44 µs (Level 1), a servo voltage of 60 V (Level 4), and a wire feed rate of 7 m/s (Level 4) are suggested to achieve optimal machining of SLMed AlSi10Mg. Furthermore, the derived optimisation results were diligently verified using a confirmatory experiment, and a 38.57% improvement in multi-response characteristics was found when compared to the initial Wire-EDM parameter settings. The methodology suggested in this work offers a standard approach that has the potential to be implemented for the rapid and precise prediction and optimisation of surface roughness while achieving better material removal during Wire-EDM of SLMed AlSi10Mg.