Multi-objective WEDM Process Parameter Optimization for Machining of LM5 Aluminium Alloy Using Grey Relational Analysis

Wire electrical discharge machining is frequently utilized, particularly with conductive materials when precision is crucial. In this investigation, the Taguchi orthogonal array (OA) develops the trials for WEDM process parameter optimization on LM5 aluminium alloy. Pulse on time (Ton), pulse off time (Toff), gap voltage (GV), and wire feed (WF) have been determined to be the process input variables, whilst material removal rate (MRR), surface roughness (SR), and kerf width (Kw) are the process output variables. ANOVA has been utilized to investigate factors that are significant and non-significant. The LM5 aluminium alloy is most frequently used in marine applications. Grey relational analysis (GRA) determines the WEDM process ideal parameter setup, which maximizes MRR whilst minimizing SR and Kw. By using the GRA approach, the optimal process parameters were discovered to be Ton of 110 µs, Toff of 50 µs, gap voltage of 40 V, and wire feed of 9 m/min. Following the validation trial, a very close association was found at an ideal condition utilizing GRA.