Multiple Regression Analysis for Ti-6Al-4V Wire Electrical Discharge Machining (Grade 5) for Light Weight Automobile Applications

Wire Electrical Discharge Machining (WEDM) is a variant of the electrical discharge machining (EDM) process, which represents an innovative method for the removal of material from a workpiece. The aforementioned process is frequently employed for the machining of harder materials that possess intricate geometries. Titanium alloys are a class of lightweight materials that find extensive utilization in many technical applications. Titanium Grade-5 is a titanium-based alloy that exhibits enhanced mechanical strength and improved resistance to corrosion. The objective of this exploratory analysis is to establish empirical correlations between the selected input variables, namely ‘Pulse on,’ ‘Pulse off,’ and peak current, and the desired output measures, which are material removal rate and surface roughness. The experimental design employed the Taguchi method to effectively organize the combination of tests by considering input factors. Multiple regression analysis has been developed to establish the relationship between selected input and output variables. Contour and interaction analysis were done to divulge the interaction effect of independent factors on individual output metrics. The results of the multiple regression analyses were then analyzed to ascertain the link amongst the various input factors and the outputs.