Modelling and optimization for material removal rate while processing bio-compatible Ti-6Al-7Nb using wire electric discharge machining (WEDM)

Abstract This study utilizes machine learning methodologies, such as artificial neural networks (ANN) and TLBO (teaching Learning Based optimisation), to develop a model and Optimisation of the Material Removal Rate (MRR) in wire electrical discharge machining (WEDM) of Ti-6Al-7Nb. The material removal rate was determined by conducting WEDM experiments with different levels of control parameters, including spark on time, spark off time, peak current, servo voltage, and wire feed rate using a Full Factorial approach through 81 runs. The most effective architecture for the ANN model was 4–10–1, and the parameters were adjusted depending on R 2 . The Artificial Neural Network (ANN) predictions were compared to those produced by the Multiple Linear Regression (MLR) model. The performance of these models was assessed by calculating the correlation between the experimental values and predicted values by models (R 2 ). MRR value is optimised using TLBO (Teaching Learning Based Optimisation), keeping the relation developed by MLR as the objective function and leading to an improved material removal rate. The proposed method ANN & TLBO would help accurately predict and optimise MRR while processing Ti-6Al-7Nb. These machine learning-based methods significantly enhance complex machining processes by providing predictive capabilities & optimizing parameters, hence playing a vital role in achieving higher efficiency, quality, and adaptability in manufacturing environments.