PCA-GRA Integrated Multi Response Optimization of Wire-Cut EDM of Ti–6Al–4V Alloy for Sustainable Production

Abstract

WEDM is a popularly used advanced machining technique to process hard-to-machine materials to net near shape with the highest accuracy and enhanced surface finish. Ti–6Al–4V alloy is an electrically conductive hard-to-machine material widely employed in diverse industries. The novelty of this paper is the application of hybrid optimization methodology integrating PCA to determine weights for multiple response optimization of surface roughness and power consumption during WEDM of Ti–6Al–4V alloy using GRA. ANOVA result established current and pulse on time as the most influential control factors affecting GRG with 46.47% and 24.65% contribution respectively. The contribution of pulse off time and wire speed is on GRG is found as 13.97% and 10.48% respectively. The optimal setting for achieving highest GRG is obtained as A1B3C1D1. The GRG (0.984) improved by 8.61% from the initial value of 0.906 while SR and PC improved significantly by 10.44% and 23.77% respectively at the optimal setting.