WEDM process parameter optimization of FSPed copper-BN composites

A systematic view on evaluating the machining characteristics of Wire Cut Electrical Discharge Machining (WEDM) employing Taguchi Method and Grey Relational Analysis based multiobjective optimization is provided in this research article. The outcome of various WEDM processing parameters including pulse discharge on time (Pulse(ON)), pulse discharge off time (Pulse(OFF)), wire feed rate (Wire(FR)) along with the material characteristics of varying Boron Nitride (BN) volume fractions while machining a friction stir processed (FSPed) copper-BN surface composite was investigated. The output responses considered in this research include Material Removal Rate (MRR) and Surface roughness (R-a) that was obtained from the L27 orthogonal array based on the above said input factors. ANOVA was performed, and Pulse(ON) and BN volume fraction were found most significant for MRR, while Pulse(ON) and Pulse(OFF) influence the most in attaining minimal R-a values. Based on the obtained experimental values for MRR and R-a, a mathematical model was developed based on the control factors and was proved to be precise in predicting the output response. An optimal combination of input control factors was finalized through grey relational analysis, and the same proved to achieve the utmost MRR (20.19 mm(3)/min) and nominal R-a(3.01 mu s) values.