Optimization of Wire Electrical Discharge Machining Parameters for Cupronickel Using Taguchi-Based Grey Relational Analysis

Wire Electrical Discharge Machining (WEDM) is an important method used to make complex shapes in conductive materials like Cupronickel, which is well-known for its ability to resist corrosion and conduct heat. The objective of this study is to enhance the effectiveness and accuracy of Wire Electrical Discharge Machining (WEDM) for Cupronickel material by utilizing a 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 key machining outcomes such as surface roughness (Ra), material removal rate (MRR). A comprehensive dataset is generated for analysis through a systematic series of experiments designed using the Taguchi method. Grey relational grades are calculated to measure the connections between the input parameters and machining responses, making it easier to determine the best parameter settings. The Taguchi-based GRA approach provides a systematic approach for optimizing multiple responses, taking into account the conflicting nature of objectives. The results of this study help improve the efficiency of WEDM processes for Cupronickel material by providing information on the sensitivity and interaction of parameters. Manufacturers can improve machining efficiency and quality while reducing production costs by identifying the most effective parameter combinations. The Taguchi-based Grey Relational Analysis is a reliable method for optimizing parameters in Wire Electrical Discharge Machining (WEDM). It provides manufacturers with a valuable tool to enhance productivity and quality in machining operations involving Cupronickel material. This study improves the comprehension of Wire Electrical Discharge Machining (WEDM) procedures and offers practical recommendations for attaining exceptional machining results in different engineering fields.