Optimisation of WEDM process parameters during machining of Cu-Ni-Si/TiC FGM using Taguchi's method

Functionally graded Cu11Ni4Si/10wt%TiC composite is fabricated using centrifugal casting and machined using wire-electrical discharge machine. The research objective is to find the optimal process parameter during machining and to study its influence on material removal rate (MRR) and surface roughness (Ra). The experiments were conducted on L9 orthogonal array by varying process parameters such as pulse on time (TON-115,120,125 µs), peak current (IP-100, 150, 200A) and wire feed rate (WF-2, 3, 4 mm/min). The trend of TON for MRR increased initially and then decreased, whereas for Ra, the trend is increasing. The relationship of IP and MRR initially decreased and then increased, whereas for Ra decreased steadily. The trend for WF was found to be linearly increasing for both MRR and Ra. Analysis of variance and S/N ratio revealed that the WF(98.19%) was the most significant parameter influencing MRR followed by TON and IP. TON(74.63%) was the most significant parameter influencing Ra followed by IP and WF.