Optimization of Wire Electrical Discharge Machining Parameters for SAE 1010 Material Using Taguchi-Based Grey Relational Approach

Wire Electrical Discharge Machining (WEDM) has attracted considerable attention in contemporary manufacturing because of its capacity to accurately form conductive materials. This study aims to optimize the parameters of Wire Electrical Discharge Machining (WEDM) for SAE 1010 material, which is a commonly used low-carbon steel. The Taguchi-based Grey Relational Approach (GRA) is employed for this purpose. The goal is to optimize machining efficiency and quality while minimizing production costs. The research methodology combines the Taguchi method for experimental design with the GRA for multi-response optimization. The Taguchi L27 orthogonal array is utilized to carry out experiments, taking into account three controllable factors: pulse-on time, pulse-off time, and discharge current. In addition, the performance characteristics to be optimized include surface roughness (Ra) and material removal rate (MRR). The experimental results are analyzed using the GRA (Grey Relational Analysis) to determine the correlation between process parameters and performance characteristics. The grey relational grades are computed to identify the most favorable parameter settings that result in the maximum machining performance. The analysis offers valuable information on the sensitivity of each parameter and their interactions, making it easier to identify the best process conditions for WEDM of SAE 1010 material. The proposed Taguchi-based GRA approach provides a systematic and efficient methodology for optimizing WEDM parameters, allowing manufacturers to improve productivity and product quality while reducing production costs. The results of this study enhance the development of machining techniques for SAE 1010 material and provide a valuable resource for improving similar manufacturing processes in different industries.