Multi-Response Optimization-Based WEDM Process for Enhancing the Machining Properties of Ti-6Al-4V and Al6061

Abstract

Ti-6Al-4V and Al6061 are alloys known for their excellent strength-to-weight ratio. Standard processing procedures find these alloys to be difficult and complex, despite their good properties. The creation of complicated and complex geometries, which is challenging using standard processes, requires nonconventional approaches. In this research, wire electrical discharge machining (WEDM)'s potential applications are utilized for enhancing and analysing the machining properties of Ti-6Al-4V and AA6061. To maximize Material Removal Rate (MRR) and minimize Surface Roughness (SR), it is necessary to optimize several process parameters. Combining Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) with Grey Relational Analysis (GRA) allows for the optimization of a large number of parameters. Based on the findings, the ideal settings for cutting Al6061 grade steel are as follows: 80V, 700 RPM wire speed, 2 A maximum current, 20 µs pulse on time (TON), and 15 µs pulse off time (TOFF). With a minimal Dimensional Deviation (DD) of 0.04 and an ideal SR value of 1.01 Ra, the results are satisfactory. The ideal settings for cutting Ti-6Al-4V include a voltage of 80V, a wire speed of 1400 RPM, a maximum current of 4 A TON for 40 µs, a TOFF of 25 µs, and a steady current of 4 A. With these particular settings, the smoothest surface is achieved with a SR of 1.9 Ra and a DD of 0.08.