Development of Multiple Regression Models for Wire Spark Erosion Machining of AA2024 Alloy

Abstract

AA2024 is an aluminium alloy, most commonly employed as material for aircraft structural applications. The exceptional properties of these alloys made this material to be suitable for consequent applications. The components used for aerospace applications need very closer tolerances and are more accurate in shape and size. Wire electrical discharge machining (WEDM) is a contemporary approach of material removal which is conceived from the concept of spark erosion machining process which is known as WEDM, predominantly employed for machining of difficult to machine materials and also especially used for making complicated shapes on any electrically conductive material. In this present exploration, an analysis has been performed on WEDM of AA2024 alloy. Pulse on time (µs), pulse off time (µs), flushing pressure (kg/cm2), wire feed (mm/min) and servo voltage (V) are considered as independent process parameters in this present exploration. Surface roughness (microns) is deemed as desired performance measure which is to be improved. Taguchi’s design approach has been adopted for designing and analysing the data attained from the experimentation. An L27 orthogonal array (OA) has been employed to perform the experimental trials. The effects of process variables on desired performance measures such as surface roughness were analysed by Taguchi’s response analysis. The significance of input process variables on desired performance measure is examined by ANOVA analysis. Multiple regression analysis has been performed for correlating the relationship amongst the selected independent process variable and preferred performance characteristic. The comparison results proved that the values predicted from the developed regression models were closer with the experimental observations.