Multi-objective optimization of process parameters of wire EDM for machining of AMCs (LM5/ZrO2) using grey relational analysis

Abstract

For a long period of time, researchers and practicing engineers have been fascinated by the difficulty of determining appropriate parameters for their new composite materials. Aluminium matrix composites (LM5/3, 6, 9% ZrO2) made-up by stir casting process are machined using WEDM in this research study. To decide the optimal parameters for the fabricated composite, experiments were carried out using Taguchi technique L27 orthogonal array by varying the Pulse on time, Pulse off time, Gap voltage and Wire feed. Achieving good surface roughness, as well as better MRR and less Cutting Width (kerf) in the WEDM machining are of absolute importance. Grey relational grade (GRG) was used to determine the outcome of machining parameters that influence the normal characteristics of the WEDM system, as well as the relative contribution of machining parameters in dominant WEDM method responses. The best machining parameters combination levels, for maximun MRR, minimum SR and Kerf were calculated. GRG determines the levels of parameters that devour the most impact on the responses. However, as a final step, a confirmation experiment was carried out for the best combination of parameters.