Achieving multi-response optimization of control parameters for Wire-EDM on additive manufactured AlSi10Mg alloy using Taguchi-grey relational theory

Abstract The current research aims to optimize the multi-response during Wire Electrical Discharge Machining (Wire-EDM) of SLMed AlSi10Mg by using Taguchi integrated Grey Relational Analysis (GRA). Selective Laser Melting (SLM) is one of the most well-known and practical Additive Manufacturing (AM) methods, with the potential to replace many traditional production processes. The complex metallic support structures created during SLM require special attention as they are difficult to remove by hand. Therefore, this study performs post-processing using the Wire-EDM precision machining technique to evaluate the machinability of the SLMed AlSi10Mg as-built part. The multi-response optimization in this study aims to achieve the maximum material removal rate and the lowest surface roughness while considering four important influencing factors (pulse On time, pulse Off time, servo voltage, and wire feed rate) at four distinct levels. The Taguchi integrated Grey Relational Analysis (GRA) revealed that a pulse On time of 118 μs (Level 3), a pulse Off time of 44 μs (Level 1), a servo voltage of 60 V (Level 4), and a wire feed rate of 7 m s −1 (Level 4) are recommended to achieve optimal machining of SLMed AlSi10Mg. Furthermore, the derived optimization results were carefully verified through a confirmatory experiment, which showed a 38.57% improvement in multi-response characteristics compared to the initial Wire-EDM parameter settings. The methodology proposed in this work offers a standardized approach that has the potential to be implemented for the rapid and precise prediction and optimization of surface roughness, while achieving better material removal during Wire-EDM of SLMed AlSi10Mg.