Optimization of machining parameters of Wire-EDM based on Grey relational and statistical analyses

Grey relational analyses are applied to determine the optimal selection of machining parameters for the Wire Electrical Discharge Machining (Wire-EDM) process. The Grey theory can provide a solution for a system in which the model is unsure or the information is incomplete. Besides, it provides an efficient solution to the uncertainty, multi-input and discrete data problem. Based on Taguchi quality design concept, an L18 mixed-orthogonal array table was chosen for the experiments. With both Grey relational analysis and a statistical method, it is found that the table feedrate had a significant influence on the metal removal rate, whilst the gap width and surface roughness were mainly influenced by pulse-on time. Moreover, the optimal machining parameters' setting for maximum metal removal rate and minimum surface roughness (or a desired surface roughness or a desired gap width) could be obtained by this approach.