Abstract
This research work presents the comparative usage of brass and molybdenum wires in the Wire electrical discharge machining (WEDM) process study on surface roughness and material removal rate (MRR) performance of titanium alloy. The optimum parameters of the model such as pulse current, pulse on-time and pulse off-time have been determined through L9 orthogonal array of Taguchi design of experiment methodology. Wear rate of brass wire is found to increase with rise in input energy in machining titanium alloy than in the case of molybdenum wire. The experimental analysis showed that the combination of higher levels of pulse current is essential to achieve simultaneous maximisation of MRR and minimisation of surface roughness by using Grey relational analysis coupled with principal component analysis. The surface roughness topography has been described by performing scanning electron microscope study. The WEDM machined surface revealed that craters are found on the machined surface of titanium alloy when using brass wire than the high strength, high wire tension and more erosion resistant molybdenum wire.
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