Parametric Optimization of WEDM on α-β Titanium Alloy using Desirability Approach

Abstract

Wire-electro discharge machining (WEDM) is a specialized non-traditional machining process to produce intricate shapes and for producing components which are difficult to machining by conventional machining methods. Modeling and optimization of machining process is one of the important aspects in manufacturing. In order to achieve this, proper planning of experimentation is desirable to analysis the results. In this work, to conduct experiments a central composite face centered (CCF) design has been used in order to optimize the WEDM process. Five input parameters considered as pulse-on time, pulse-off time, peak current, servo voltage and wire feed and responses to be measured as surface roughness and material removal rate. Second order models were developed to establish the relation between responses and process parameters using multiple linear regression. The effect of process parameters on the responses are evaluated and optimum cutting conditions for minimizing surface roughness and maximizing material removal rate were determined using response tables, response graphs, interaction tables, 3-D surface plots and desirability analysis. Further, in-depth analysis of factor affects has been carried out by means of interaction tables and interaction graphs. Backward linear regression option of SPSS, is used to develop the surface roughness (SR) and material removal rate (MRR) models. Simultaneous optimization of responses has been performed using desirability function.