Multi Response Optimization of Wire Electrical Discharge Machining Process Parameters Using Taguchi based Grey Relational Analysis

This paper presents a study that investigates the effect of the WEDM process parameters on the surface roughness average and the kerf width of the stainless steel (SS 304). Nine experimental runs based on an orthogonal array of Taguchi method are performed and grey relational analysis method is subsequently applied to determine an optimal WEDM parameter setting. Surface roughness and kerf width are selected as the quality targets. An optimal parameter combination of the WEDM process is obtained using Grey relational analysis. By analyzing the Grey relational grade matrix, the degree of influence for each controllable process factor onto individual quality targets can be found. The pulse ON time is found to be the most influential factor for both the surface roughness and the kerf width. Further, the results of the analysis of variance (ANOVA) reveals that the pulse ON time is the most significant controlled factor for affecting the multiple responses in the WEDM according to the weighted sum grade of the surface roughness and the kerf width.