Modeling of Electric Discharge Wire Cut of Aviation Grade Alloy Using Fuzzy Technique

Abstract

Fuzzy modeling technique is obtaining a huge revelation as prospective modeling for solving and modeling of manufacturing issues. In this research paper, fuzzy modeling technique is applied for analyzing and predicting the MRR, SR and CR during machining of aviation-grade aluminum alloy. Pulse-on time ([Formula: see text]), pulse-off time ([Formula: see text]), peak-current ([Formula: see text]) and servo-voltage ([Formula: see text]) are used as process variables. The different combinations of process variables for experimentation are designed using Box–Behnken design (BBD) of Response Surface Methodology (RSM). Results showed that [Formula: see text] is the most significant parameter for CR, MRR and SR, followed by [Formula: see text] and [Formula: see text]. It is observed that [Formula: see text] has less significance in response parameters. The confirmation experiments have also been carried out to justify the result procured by the fuzzy model. The root mean square error (RMSE) of CR, MRR and SR is 3.633, 3.586 and 3.366, respectively. Additionally, microstructure variations of machined surface are evaluated by scanning electron microscope (SEM). Micro-cracks, wire tool marks, craters and lump of debris are seen on WEDMed surfaces.