Analysis and optimization of wire Electro-Discharge Machining process parameters for the efficient cutting of Aluminum 5454 alloy

Aluminum 5454 alloys are considered a subject in this research, widely used in the industry, to develop die tools, molds, engine blocks, aircraft structural components, and many other commercial products. In this research, the WEDM process parameters effects on the Aluminum 5454 alloy tapered workpiece have been investigated. Tapered workpieces with angles of 30°, 45° and 60° are prepared, in which slots are generated using the WEDM process. The taper angle, peak discharge current and pulse-off time are selected as the controllable parameters in this research. Whereas other parameters are kept constant. Impact of the parameters over; kerf width, surface finish, MRR and wire have been investigated. ANOVA is applied to statistically analyze the influence of the factors over the four variables. Regression models for the four variables are determined and the Genetic Algorithm is applied to determine the feasible WEDM process parameters for the desirable magnitudes of the four variables. The regression models and optimized parameter values for different taper angles workpieces of Aluminum 5454 alloy can be used in the industry to increase the productivity and enhanced results.