MACHINABILITY ASSESSMENT OF WIRE-EDM USING BRASS WIRE FOR C-45 STEEL APPLYING VIKOR-AHP

Abstract

Excellent qualities including a good balance of strength and toughness, good wear resistance, cost-effectiveness, high machinability, functionality, durability, and reliability make C-45 steel a desirable option for automotive, tool and die-making industries, agricultural, railway, power transmission equipment, etc. When accuracy and precision are crucial, C-45 can be machined using wire electrical discharge machining (WEDM). In this study, input parameters like pulse-on time ([Formula: see text]), pulse-off time ([Formula: see text]), wire feed (WF), and wire tension (WT) were taken to investigate three crucial machining outputs namely average cutting speed (V), kerf width (KW), and material removal rate (MRR), using 0.25 mm brass wire. Taguchi’s ([Formula: see text]) orthogonal array has been utilized to perform the trial runs. A hybrid approach combining VIKOR in conjunction with the analytical hierarchy process (AHP) is used to identify optimal WEDM process parameters. Finally, the optimal settings of the input process parameters are [Formula: see text] = 110 [Formula: see text]s, [Formula: see text]= 40 [Formula: see text]s, WF = 5 mm/min, and WT = 6 N, respectively. For the desired MRR, KW, and V, the ideal input factors were also achieved using Taguchi’s [Formula: see text]/[Formula: see text] ratio. Additionally, SEM micrographs revealed different effects on the machined surface during machining on optimal parameter settings. This study will help the decision-makers to find the best compromise solution to handle complex decision problems with multiple criteria and prioritize alternatives using a systematic approach which leads to a more effective and rational decision-making process.