Optimization of Wire-EDM Process Parameters for Ti6Al4V Alloy Cutting Using Mayfly Algorithm

Abstract

AbstractThe present work is an extension of the work carried out by the authors previously. In the present study, the optimization of input parameters for wire-EDM cutting of a 2.5 mm thick Ti6Al4V alloy sheet was carried out to have desired cut quality and cutting speed. The experiments were statistically designed using an L8 orthogonal array. Voltage, current, capacitance, duty cycle, frequency, wire tension, and wire feed, were chosen as the input parameters. Kerf width, taper angle, surface roughness, and cutting speed were considered as the outputs. A newly developed, nature-inspired algorithm, called the Mayfly optimization algorithm, was used to minimize the kerf width, taper angle, and surface roughness, along with maximization of cutting speed. The minimum value of current, duty cycle, and frequency were found to be favorable to predict the desired output due to lower spark-energy generation. At the same time, the maximum value of voltage, wire feed, and wire tension were formulated by the algorithm for obtaining desired output. Upon confirmation test using the optimized process parameters, satisfactory experimental results were found for the predicted results within acceptable error.KeywordsTi6Al4VWire-EDM cuttingOptimization