Use of PCA-grey analysis and RSM to model cutting time and surface finish of Inconel 800 during wire electro discharge cutting

Abstract This paper exhibits a test examination and investigation on the impacts of Wire Electro Discharge Cutting (WEDC) parameter on cutting time and surface roughness (Ra) of Inconel 800. Four cutting parameters, pulse-on time, pulse-off time, pulsed current and servo voltage have been selected to study their effects on cutting time and surface roughness (Ra). The response variables like cutting time and surface roughness (Ra) are then analysed using response surface methodology (RSM). The general belief that increase in pulse-on time reduces cutting time has been revisited. It has been seen, here, that cutting time diminishes with the expansion of pulse-on time obviously up to the limit and from there on again increments. The surface roughness, on the other hand, increases with the increase in pulse-on time appreciably. It is for the most part seen that when the rate of machining is moderate, i.e. it requires longer investment to machine then the surface completion is superior to that acquired while machining at a quicker rate. But, as increased machining time leads to an increase in the manufacturing cost, a trade-off between cutting time and surface roughness, was successfully made by utilising a hybrid PCA-grey relational analysis (GRA). This gave the best combination of cutting parameters. Also hybrid GRA-PCA shows less percentage error compare to traditional GRA.

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