Title: Multi-quality characteristics optimisation on WEDM for Ti-6Al-4V using Taguchi-grey relational theory

Authors: Neeraj Sharma; Rajesh Khanna; Yogesh Kumar Sharma; Rahul Dev Gupta

Addresses: Department of Mechanical Engineering, Maharishi Markandeshwar (Deemed to be University), Mullana, Ambala-133207, India ' Department of Mechanical Engineering, D.A.V. University, Jalandhar-144012, India ' Department of Mechanical Engineering, D.A.V. University, Jalandhar-144012, India ' Department of Mechanical Engineering, Maharishi Markandeshwar (Deemed to be University), Mullana, Ambala-133207, India

Abstract: In the present research, Ti-6Al-4V alloy was processed on wire-cut electrical discharge machine (WEDM) and the machining responses were analysed. The effect of machining variables was investigated on cutting speed (CS) and surface roughness (SR). Taguchi technique-based L₉ orthogonal array was considered for the planning of experiments. Grey relational theory is used for multi-characteristics optimisation. During the research, it was observed that the best optimal setting for the process parameters is A₁ B₂ C₂. At the suggested optimal setting, the predicted value of CS was 0.2044 mm/min and SR was 2.162 μm. These values are predicted at 95% confidence level. Scanning electron microscopy (SEM) investigates the surface morphology after the WEDM process. The surface integrity reveals the white-layer, sub-surface cracks and micro-cracks on the machined surface. The crack intensity increases with the increase of discharge energy.

Keywords: wire-cut electrical discharge machine; WEDM; Ti-6Al-4V; ANOVA; GRA; multi-response optimisation; scanning electron microscopy; SEM.

DOI: 10.1504/IJMMM.2019.098067

International Journal of Machining and Machinability of Materials, 2019 Vol.21 No.1/2, pp.66 - 81

Received: 07 Feb 2018
Accepted: 23 May 2018
Published online: 01 Mar 2019 *

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