Experimental Investigation and Optimization of Wire EDM Parameters for Surface Roughness, MRR and White Layer in Machining of Aluminium Alloy

Abstract The quality of a wire EDM surface is strongly influenced by its parameter settings and material to be machined. The one characterization among the metals for studying its effect is light and heavy metals. Much of the work is concentrated on heavy metals and partly on titanium and magnesium alloys in the light metals. Here, an attempt has been made to study the effect of wire EDM parameters on aluminum alloy because of its growing applications in various industries. In the present research, parametric analysis of wire EDM parameters was performed by Taguchi method on surface roughness (SR) and material removal rate (MRR). The above performance measures are simultaneously optimized by hybrid genetic algorithm with the use of developed linear regression models. The obtained results show a good agreement with experimental values. Finally, for a suggested combination of parameters white layer measurements were also made as it adversely affects many other properties.