Multi-response optimization of WEDM process parameters during the fabrication of microchannels for industrial applications

Abstract

The dissipation of heat from integrated circuits and other electronic devices are transfer by devices known as microchannels. Microchannels can be fabricated by various traditional and modern machining methods. Among the traditional and modern machining methods, the wire electrical discharge machining (WEDM) has been recently explored as a good alternative machining process. WEDM has tremendous potential on account of the versatility of its applications. In this study, the effect of WEDM parameters such as peak current (Ip), pulse on time (Ton) and pulse off time (Toff) on the surface roughness (Ra) and material removal rate (MRR) is evaluated during the fabrication of microchannels. Response surface methodology orthogonal array has been used to carry out the experimental runs using brass wire (diameter 0.25 mm) as electrode. Single-response optimization through Genetic algorithm (GA) for maximum MRR = 7.0964261800mm3/min and minimum Ra = 3.35966619 µm have found for fabrication of brass microchannel are Ip = 200.104A, Ton = 118.4 µs, Toff = 51.81 µs, and Ip = 200.36A, Ton = 118.4 µs, Toff = 45.003 µs respectively. The confirmation results show the goodness of the developed models. A set of non-dominated preto-optimal solutions has been generated for multi-response optimization through GA. The best solution has been found for maximum MRR and minimum Ra are Ip = 178.3805A, Ton = 108.8105 µs, and Toff = 44.9989 µs. It is the multi-objective optimal solution to the fabrication of brass microchannel.