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<p>This study investigates the wire electrical discharge machining (WEDM) of ER4043–AlN composite using a Taguchi L27 design to evaluate the effects of pulse-on time (Ton), peak current (Ip), and wire speed (Ws) on material removal rate (MRR), kerf width, and surface roughness (Ra). Statistical analysis using ANOVA at a 95% confidence level revealed that pulse-on time is the only significant parameter influencing MRR (30.36%), while wire speed dominates kerf width (28.24%). For surface roughness, pulse-on time is highly significant (63.87%), followed by current with a marginal effect. Experiments were to be based on a Taguchi L<sub>27</sub> orthogonal array by changing pulse-on time (3–13 µs), peak current (8–12&#xa0;A); and wire speed (5–15&#xa0;m/min). Experimental outcomes showed that MRR was between 3.46 and 23.78&#xa0;g/min, course of the kerf ranged between 0.2647 and 0.3104&#xa0;mm, and the surface roughness acquired was observed between 1.59 and 2.49&#xa0;μm. A multi-objective optimisation gave a trade-off parameter profile of 8 µs pulse-on time, 12&#xa0;A peak current and 10&#xa0;m/min wire speed with a balanced machining performance.</p>

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Optimization of WEDM parameters for ER4043–AlN composites

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Penumuru Kumar,
  • Vejjupalli Ganesh,
  • Hariprasad Tarigonda,
  • B V Maha Lakshmi,
  • Harinadh Vemanaboina

摘要

This study investigates the wire electrical discharge machining (WEDM) of ER4043–AlN composite using a Taguchi L27 design to evaluate the effects of pulse-on time (Ton), peak current (Ip), and wire speed (Ws) on material removal rate (MRR), kerf width, and surface roughness (Ra). Statistical analysis using ANOVA at a 95% confidence level revealed that pulse-on time is the only significant parameter influencing MRR (30.36%), while wire speed dominates kerf width (28.24%). For surface roughness, pulse-on time is highly significant (63.87%), followed by current with a marginal effect. Experiments were to be based on a Taguchi L27 orthogonal array by changing pulse-on time (3–13 µs), peak current (8–12 A); and wire speed (5–15 m/min). Experimental outcomes showed that MRR was between 3.46 and 23.78 g/min, course of the kerf ranged between 0.2647 and 0.3104 mm, and the surface roughness acquired was observed between 1.59 and 2.49 μm. A multi-objective optimisation gave a trade-off parameter profile of 8 µs pulse-on time, 12 A peak current and 10 m/min wire speed with a balanced machining performance.