MULTI-PARAMETRIC OPTIMIZATION OF WIRE-EDM MACHINING ON ARTIFICIALLY-AGED AL6061/B4C COMPOSITE USING RSM AND GREY RELATIONAL ANALYSIS

Subraya Krishna Bhat; Shreyas D Sai; Gowri Shankar M C; Deepak Doreswamy

doi:10.5937/jaes0-44452

Subraya Krishna Bhat Department of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, Karnataka - 576104, India https://orcid.org/0000-0003-1798-3480
Shreyas D Sai Department of Mechatronics, Manipal Institute of Technology Manipal Academy of Higher Education, Manipal, Karnataka, India-576104
Gowri Shankar M C Department of Mechanical and Industrial Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, Karnataka - 576104, India. https://orcid.org/0000-0001-9951-800X
Deepak Doreswamy Department of Mechatronics, Manipal Institute of Technology Manipal Academy of Higher Education, Manipal, Karnataka, India-576104 https://orcid.org/0000-0001-7194-463X

DOI: https://doi.org/10.5937/jaes0-44452

Keywords: Wire-EDM, Al6061/B4C, grey relational analysis, pulse-on time, pulse-off time, current

Abstract

Wire-electric discharge machining (W-EDM) is an advanced technology used for machining hard-to-cut materials with high hardness. Therefore, it is critical to characterize and model the Wire-ED machining performance for new materials having remarkable mechanical properties with respect to the multiple control parameters involved in the process. In this light, the present study investigates the multi-parametric optimization of current, pulse-on time (T_on), and pulse-off time (T_off) on material removal rate (MRR), kerf width (KW), surface roughness (R_a) for Wire-EDM of artificially aged Al6061/B₄C composite using response surface method (RSM) and grey relational analysis (GRA). The results of the investigation revealed that, T_off has the most significant impact on the multi-parametric response, with a percentage-wise contribution of 38% from the analysis of variance. The optimization results established that a multi-parametric combination of current – 6 A, T_on – 42.5253 µs, and T_off – 10 µs achieved the optimum response of MRR – 1.7036 mg/min, KW – 0.1727 mm, and R_a – 5.6525 µm. The results obtained herewith have practical relevance to Wire-EDM industry for manufacturing applications.

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