Modeling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation

The prediction of optimal machining conditions for required surface finish and dimensional accuracy plays a very important role in process planning of wire electrical discharge machining. The present work deals with the features of trim cutting operation of wire electrical discharge machining of gamma-titanium aluminide. A second-order mathematical model, in terms of machining parameters, was developed for surface roughness, dimensional shift and cutting speed using response surface methodology (RSM). The experimental plan was based on the face centered, central composite design (CCD). The residual analysis and experimental results indicate that the proposed models could adequately describe the performance indicators within the limits of the factors that are being investigated. Finally the trim cutting operation has been optimized for a given machining condition by desirability function approach and Pareto optimization algorithm. It was observed that performance of the developed Pareto optimization algorithm is superior compared to desirability function approach. (C) 2007 Elsevier B.V. All rights reserved.