Optimizing EDM process parameters with the use of GRA-based RSM for machining titanium alloy
Velusamy Mohankumar, M. S. Senthil Kumar, Karthik Aruchamy, Amanuel Kumsa Bojer, Enas Ali, Sherif S. M. Ghoneim, Ahmed B. Abou Sharaf
Abstract
This study optimizes the electrical discharge machining (EDM) process for Ti-6Al-4 V alloy using Response Surface Methodology (RSM) and Grey Relational Analysis (GRA). Input parameterspeak current, pulse-on time (Ton), and pulse-off time (Toff)were varied to enhance Material Removal Rate (MRR) and Surface Roughness (SR). Experiments utilized a tungsten carbide electrode and kerosene as the dielectric fluid. Results indicated peak current significantly influences MRR and SR. The highest MRR of 8.52 mm³/min was achieved at 22 A, while the lowest SR of 2.65 µm occurred at 12 A. ANOVA confirmed the peak current ( P = 0.000) and Toff ( P = 0.016) significantly affect MRR, with an R² value of 98.9 %, validating model reliability. Multi-objective optimization identified ideal settings for maximizing MRR and minimizing SR, further validated by confirmation experiments. The integrated RSM-GRA approach proved effective for EDM performance improvement.