Process optimization of Titanium alloy machining with Wire Electro Discharge Machining using Taguchi’s Grey Relational Analysis

Titanium alloys have exceptional mechanical properties together with high strength to weight ratio and have widespread applications in the aerospace sector. Generally, these alloys have drawback with machinability. Wire-Electro Discharge Machining (WEDM) is in use to make complex shapes. Titanium alloy efficient machining includes choosing appropriate process parameters to optimize the performance characteristics. The present experimental investigation deals with process optimization of Wire Electro Discharge Machining (WEDM) process on Titanium grade 5 material using brass wire of 0.25 mm. Servo Voltage, Peak current, Pulse-on-time and Pulse-off-time, are considered as input parameters. Experiments are carried out utilizing Taguchi's L27 orthogonal array. Every process parameter is analyzed at 3 levels by using Grey Relational Analysis (GRA). The finest process parameters that optimize the Wire Wear Ratio (WWR) and Surface Roughness (SR) are identified. ANOVA is accomplished to estimate the significance of all input parameters on output performance characteristics. Confirmation tests are conducted. Experimental results are in acceptable concurrence with the confirmation test values.