Multi-objective optimization in wire electric discharge machining of Ti–6AL–4v using grey relational analysis for square and circular profiles

In this work, an attempt has been made for optimization of process parameters in Wire Electric Discharge Machining (WEDM) of Ti–6Al–4V while producing square and circular profiles. The input parameters, namely pulse on time, pulse off time, peak current and servo voltage, were considered to study the responses cutting speed (CS) and surface roughness (SR). Each input parameter was set at three levels. Experiments were conducted as per central composite face (CCF) centered design. Based upon the experimental data, Gray relational analysis (GRA), a multi-objective optimization technique has been employed to find the best level of process parameters to optimize the machining profiles. Analysis of variance (ANOVA) has been conducted for investigating the effect of process parameters on overall machining performance. Finally, it was identified that the process parameters such as pulse on time, current and voltage have more impact on the square and circular profiles.

Study on Effect of Blended Powder Mixed Dielectric Fluids in Wire EDM Process

Wire Electric Discharge Machining (WEDM) process is used for machining various materials used in applications that require dimensional accuracy, high surface finish and have intricate shapes. This work includes the study of WEDM process when dielectric fluid is mixed with combination of two metallic powders viz. Silicon Carbide and Aluminium Oxide. The effect of this powder mixing on Material Removal Rate (MRR) and Surface Roughness (SR) is being analysed and optimum level of control parameters is found out. AISI D3 which is also called as die steel is used as workpiece material. Distilled water (30 TDS) is used as dielectric fluid and Zinc cozted Brass wire (CuZn37) is used as wire electrode. DOE is done using Taguchi. Significant parameters are found out using ANNOVA. Lastly GRA is used to find optimum set of parameters.