Optimization and modelling of WCEDM process parameters for GZR-AA7475 HMMC using GRA and Taguchi approach
Abstract
Purpose
This study aims to investigate the optimal process parameters of the wire-cut electrical discharge machining (WCEDM) for the machining of the GZR-AA7475 hybrid metal matrix composite (HMMC). HMMCs are prepared with 2 Wt.% graphite and 4 Wt.% zirconium dioxide reinforced with aluminium alloy 7475 (GZR-AA7475) composite by using the stir casting method. The objective is to enhance the mechanical properties of the material while preserving its unique features. WCEDM with a 0.18 mm molybdenum wire electrode is used for machining the composite.
Design/methodology/approach
To conduct experimental studies, a Taguchi L27 orthogonal array was adopted. Input variables such as peak current (Ip), pulse-on-time (TON) and flushing pressure (PF) were used. The effect of process parameters on the output responses, such as material removal rate (MRR), surface roughness rate (SRR) and wire wear ratio (WWR), were investigated. The grey relational analysis (GRA) is used to obtain the optimal combination of the process parameters. Analysis of variance (ANOVA) was also used to identify the significant process parameters affecting the output responses.
Findings
Results from the current study concluded that the optimal condition for grey relational grade is obtained at TON = 105 µs, Ip = 100 A and PF = 90 kg/cm2. Peak current is the most prominent parameter influencing the MRR, whereas SRR and WRR are highly influenced by flushing pressure.
Originality/value
Identifying the optimal process parameters in WCEDM for machining of GZR-AA7475 HMMC. ANOVA and GRA are used to obtain the optimal combination of the process parameters.
Keywords
Acknowledgements
The authors appreciate the support from the Department of Mechanical Engineering, College of Engineering, Andhra University, Visakhapatnam, for providing help during the research and preparation of the paper. The authors thank S.R.K.R. Engineering College, Bhimavaram for helping with this work.
Funding: Not applicable
Conflicts of interest/Competing interests: The authors declare that they have no competing interests.
Availability of data and material: The data that support the findings of this study are available from the corresponding author (Singuru Madhava Rao) upon reasonable request.
Ethics approval: All procedures performed in studies involving human participants were in accordance with the ethical standards of the institutional and/or national research committee and with the 1964 Helsinki declaration and its later amendments or comparable ethical standards.
Consent for publication: I, the undersigned, give my consent for the publication of identifiable details, which can include photograph(s) and/or videos and/or case history and/or details within the text (“material”) to be published in the above journal and article.
Citation
Singuru, M., V.V.S., K.R. and Chekuri, R.B.R. (2024), "Optimization and modelling of WCEDM process parameters for GZR-AA7475 HMMC using GRA and Taguchi approach", World Journal of Engineering, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/WJE-09-2023-0354
Publisher
:Emerald Publishing Limited
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