Application of a hybrid Taguchi grey approach for determining the optimal parameters on wire electrical discharge machining of Ti6Al4V

Due to the widespread use of titanium alloy in various applications, such as maritime transportation and aviation, the process of mass production of this material has become more challenging. Traditional methods of removing materials have high wear rates and slow processing speeds. This has prompted the development of new techniques that can handle the complexity of this material. Wire Electrical Discharge Machining (WEDM) is a method frequently utilized in the removal of electrically conductive and hard materials. It can be used to create intricate designs by taking into account the input parameters, such as peak current and pulse duration. The various performance indicators of WEDM such as rate of material removal, surface roughness, dimensional deviation, and form/orientation tolerance errors are analyzed using a technique developed by Taguchi. The factors that influence the performance of this process are then analyzed through an ANOVA analysis. The goal of this research paper is to develop an optimization model based on a hybrid Taguchi grey approach that can be used to determine optimal process variable for achieving best performance in machining. The results of the explorative analysis shows that the various process variables can influence the performance of WEDM in Titanium grade 5. Contour plot and interaction analysis also adopted to divulge the interactive effect of factors on chosen performance measures. Furthermore, regression models were evolved to reveal the relationship amongst the dependent and independent variables. The findings of this study can be utilized by manufacturers to choose the suitable factors for the WEDM process.