Optimization of Wire Electrical Discharge Machining Process Parameters for Al7075/Al2O3/SiC Composite using Aspect Ratios of Taguchi Method, Taguchi-Pareto and Taguchi-ABC Methods
doi: 10.14456/mijet.2023.1
Keywords:
wire EDM, aspect ratios, optimisation, orthogonal array, factors, levelsAbstract
Aspect ratio determination has recently become a new way of evaluating the optimal parametric setting using the Taguchi method and following the orthogonal array-signal-to-noise ratio-response table route. Unfortunately in the machining domain, there is no account of any computations made using completely aspect ratios. But available records show a blend of direct and aspect ratios. To deviate from the extant literature practice, this article proposes a situation where all the factors are considered as aspect ratios for the determination of optimal process parameters in a wire electrical discharge machining process. Aspect ratios are integrated into the evaluation scheme at the factor-level stage where the ratios of each direct factor are obtained relative to the others. The values obtained are then transformed in an orthogonal matrix format to the signal-to-noise ratios, which are summarized as averages in the response table to obtain the optional parametric settings. The optimal parametric settings for the Taguchi method is (A/B)1(A/C)1(A/D)1which is interpreted as 2.00 for a pulse on-time/pulse off time, 2.00µѕ/A for a pulse on-time/current and 1.00µѕmin/ m for a pulse on-time/ wire drum speed. The ranks of the factors after the Taguchi analysis are A/C(pulse on-time/current) ranked 1st, A/B (pulse on-time/pulse off time) ranked 2nd and A/D (pulse on-time/ wire drum speed) ranked 3rd. Furthermore, the optimal parametric settings using Taguchi Pareto’s method is (A/B)1(A/C)1(A/D)1which is interpreted as 2.00 for a pulse on-time/pulse off time, 2.00µѕ/A for a pulse on-time/current and 1.00µѕmin/ m for a pulse on-time/ wire drum speed. The ranks of the factors after Taguchi-Pareto analysis are A/D (pulse on-time/ wire drum speed) ranked 1st, A/C (pulse on-time/current) ranked 2nd and A/B (pulse on-time/pulse off time) ranked 3rd. Now, focusing on the results of group A alone in the Taguchi-ABC method, the optimal parametric settings for group A are (A/B)1 (A/C)1(A/D)1 which is interpreted as 2.00 for pulse on-time/pulse off time, 2.00 µѕ/A for a pulse on-time/current and 1.00 µѕ min/m for a pulse on-time/ wire drum speed. The ranks of the factors after Taguchi ABC analysis for Group A are A/C(pulse on-time/current) ranked 1st, A/B (pulse on-time/pulse off time) ranked 2nd and A/D (pulse on-time/ wire drum speed) ranked 3rd. The synergy between the aspect ratios and the orthogonal arrays helps the process engineers/operators of wire. EDM machines practically and effectively optimize the process and select the most promising aspect ratios and values for further decisions. The aspect ratios respond to the methods and offer the first step towards attaining a sustainable wire EDM process.
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