Multi-response optimization of wire electrical discharge machining process parameters for Al7075/Al₂O₃/SiC hybrid composite using Taguchi-based grey relational analysis

Abstract

The effect of various wire electrical discharge machining process parameters such as pulse on time, pulse off time, pulse current and the wire drum speed on machined surface quality characteristics such as surface roughness and kerf width has been discussed. The experiments were carried out with L27 orthogonal array on hybrid metal matrix composite prepared by inert gas–assisted electromagnetic stir casting process using particulates 7.5% Al2O3 and 7.5% SiC each in Al7075 alloy. Taguchi-based grey relational analysis, a multi-response optimization technique, was used to find the optimal process parameter setting for the best quality machined characteristics. Results of analysis of variance showed that the order of significance was pulse on time, pulse current, pulse off time and the wire drum speed contributing 50.02%, 39.50%, 4.58% and 2.75%, respectively, while machining the hybrid composite. Confirmation test was carried out at selected optimal parameter setting, which showed improvement in grey relational grade, thus confirming the robustness of grey relational analysis.

Taguchi Grey Relational Analysis for Multi-Response Optimization of Wear in Co-Continuous Composite

“…Furthermore, a 21% improvement of the grey relational grade was also realized thereby resulting in an improved design of the composite for tribological applications. In addition to this, the Taguchi method coupled with GRA has also been applied for multi-objective optimization of milling parameters [20,21], the turning process [22] and the wire electrical discharge machining process [23]. …”

Optimization of WEDM process of mould material using Kriging model to improve technological performances

“…The higher discharge energy generated causes excessive material removal and resultantly leads to an increased kerf width. Furthermore, an excessive speed effectively influences on the flushing of the debris material, thereby increasing width [12,34,35].…”

“…Additionally, investigators solved the trade-off among multi-responses for the WEDM processes of YG15 steel [6], AISI D2material [7] and Inconel alloys [8,9]. Recently, optimal processing conditions for the WEDM processes of composite materials were studied [10][11][12]. The technological responses considered were the cutting speed, the material removal rate (MRR), the surface roughness properties, the kerf width and the wire wear ratio.…”

Surface Integrity Analysis and Simultaneous Optimization Using Taguchi Grey Relational Analysis

“…The relationship between machining parameters and machining performance can be found out by using grey relational analysis coupled with Taguchi [16][17][18][19][20]. Grey relational analysis is performed in a step wise manner and are calculated as follows.…”