Parametric optimization and modelling of rough cut WEDM operation of pure titanium using grey-fuzzy logic and dimensional analysis

Abstract

In this study, effects of input parameters such as pulse on time (TON), pulse off time (TOFF), peak current (IP), wire feed (WF), wire tension (WT) and servo voltage (SV) on machining characteristics such as material removal rate (MRR), surface roughness (SR) and wire weight consumption (WWC) were investigated in wire electric discharge machining (WEDM) process using commercially pure titanium as work material. The consumption of wire and its correlation with wire wear was also investigated. The responses were optimized simultaneously using grey-fuzzy logic approach. Surface integrity aspects such as microstructure analysis (including recast layer thickness, debris and cracks, crater size and shape, etc.) of the selected machined titanium samples have also been investigated to evaluate the suitability of WEDM for machining titanium. The material transfer mechanism between the zinccoated wire electrode and the work surface has been studied using energy dispersive X-ray analysis. A mechanistic model has also been developed and validated for prediction of the response parameter (MRR) over a wide range of input variables.