Optimization of Micro WEDM Process Parameters for Machining on TI-6AL-4V Alloy

This works presents the experimental investigation to determine the optimum parametric setting for the effective and efficient machining of Ti-6Al-4V alloy by using of Wire EDM process. The Taguchi method, a statitistical method for experimental design, has been used to optimize the WEDM process parameters. An L25 orthogonal array was used to determine the S/N ratio, based on Taguchi quality design Concept, so as to indicate the significant machining parameters affecting the machining performance i. e. Material removal rate, and Surface roughness. The machining results were obtained by variation of Duty cycle at five different levels (30, 40, 50, 60 and 70 %), wire tension at five different levels (3, 6, 9, 12 and 15kg-f), peak current at five different levels (50, 75, 100, 125 and 150A), and wire feed at five different levels (5, 6, 7, 8 and 9mm/min. ). It is noted that the maximum mean of material removal rate (MRR) is 59.06mm3/min and the minimum mean of surface roughness (SR) is 1.234 Ra. The optimum combination parameters for higher MRR are Duty cycle 70 %, wire tension 3 kg-f, peak current 125 A, and wire feed rate 5 mm/min. The optimum combination parameters for lower surface roughness are Duty cycle 30 %, wire tension 6 kg-f, peak current 125 A, and wire feed rate 8 mm/min.