An investigation of the surface topography of wire tool and the modelling of wire electro-spark machined Ti-alloy using ANN

Abstract

Titanium and its alloys are in demand in the field of biomedical and aerospace engineering because of its high strength-to-weight ratio and anti-corrosive properties. WESM emerged as a processing method as traditional methods could not process because of strain hardening and low material conductivity; however, wire tool consumption contributes to high costs while processing with WESM. The current Article investigates the effect of input factors on wire consumption and their significance level on wire consumption. A total of 81 experimental runs were conducted while taking input factors Spark on, Spark off time, peak current and servo voltage at three levels, each using a full factorial approach. Experimental results were analysed using ANOVA and MLR (Multi-Linear regression). Moreover, ANN modelling is done to model the wire consumption using a 4-10-1 architecture that increased the coefficient of correlation (R2) up to 0.991. Lastly, after processing, the wire tool surface is evaluated using a scanning electron microscope to assess the effect of various input energy levels and find input combinations for minimum wire consumption