Optimization of WEDM Parameters for Invar 36 Automotive Components Using Taguchi-Grey Relational Analysis

Wire Electrical Discharge Machining (WEDM) is an essential procedure used to shape intricate geometries in conductive materials such as Invar 36, which is recognized for its minimal thermal expansion characteristics used for high temperature applications especially in automobile engine parts and exhaust valves. The objective of this study is to improve the effectiveness and precision of Wire Electrical Discharge Machining (WEDM) for Invar 36 material by utilizing Taguchi-based Grey Relational Analysis (GRA). The study examines the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on important machining outcomes such as surface roughness (Ra), material removal rate (MRR). The experimentation have been planned and conduced as per Taguchi L9 orthogonal array design. Grey relational grades are computed to measure the correlation between input parameters and machining responses, enabling the determination of the most favourable parameter configurations. The Taguchi-based GRA approach offers a methodical approach for optimizing multiple responses, taking into account the conflicting nature of the objectives. The results of this study enhance the efficiency of WEDM processes for Invar 36 material by providing valuable information about the impact of process parameters and their interrelationships. Manufacturers can enhance machining efficiency and quality while decreasing production costs by identifying the most advantageous parameter combinations. The Taguchi-based Grey Relational Analysis offers a strong framework for optimizing parameters in Wire Electrical Discharge Machining (WEDM), serving as a valuable tool for manufacturers aiming to improve the performance of machining operations on Invar 36 material. This study enhances the comprehension of WEDM (Wire Electrical Discharge Machining) procedures and provides practical recommendations for attaining exceptional machining results in high-precision applications.