Abstract
To further improve prediction accuracy and optimization quality of wire electrical discharge machining of SiCp/Al composite, trim cuts were performed using Taguchi experiment method to investigate the influence of cutting parameters, such as pulse duration ( Ton), pulse interval ( Toff), water pressure ( Wp), and wire tension ( Wt)), on material removal rate and three-dimensional surface characteristics ( Sq and Sa). An optimization model to predict material removal rate and surface quality was developed using a novel hybrid Gaussian process regression and wolf pack algorithm approach based on experiment results. Compared with linear regression model and back propagation neural network, the availability of Gaussian process regression is confirmed by experimental data. Results show that the worst average predictive error of five independent tests for material removal rate, Sq, and Sa are not more than 10.66%, 19.85%, and 22.4%, respectively. The proposed method in this article is an effective method to optimize the process parameters for guiding the actual wire electrical discharge machining process.
Highlights
SiCp/Al composite is a metal matrix composite (MMC) consisting of aluminum matrix and silicon carbide particles
In Wire electric discharge machining (WEDM) process, the material removal rate (MRR), Sq, and Sa are related to the material removal per discharge, which is determined by the electric parameters
The present study proposed an effective approach and framework in predicting and optimizing process parameters of WEDM SiCp/Al composite using GPRWPA
Summary
SiCp/Al composite is a metal matrix composite (MMC) consisting of aluminum matrix and silicon carbide particles. Due to its excellent characteristic, such as high strength, low density, thermal stability, and good wear resistance, it is widely used in aircraft components, space systems, and high-end equipment. Its reinforcement particles make it hard to be machined in traditional ways, which can cause high tool wear.[1,2] The poor machinability limits its further application, so an economical machining method with a high performance is in great need.
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