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Multi-response optimization in WEDM process of Al–Si alloy using TLBO-graph theory algorithm towards sustainability

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Abstract

One of the challenges facing manufacturing industries is optimizing the power consumption for the development of sustainable manufacturing processes. To precisely measure the wire cut electric discharge matching (WEDM) performance of aluminum–silicon (Al–Si) alloy, the present study proposed a hybrid teaching and learning–based optimization (HTLBO) to take on the challenge. The HTLBO comprises teaching and learning–based optimization technique and graph theory algorithm to improve WEDM performance. The power consumption, kerf width, surface quality, and metal removal rate are considered performance characteristics. First, an auxiliary electrode was placed on the top surface of the Al–Si alloy and reduced surface defects including micro-cracks, micro-voids, and micro-globules from the machined surface around the kerf and also improved metal removal rate. The proposed methodology was used in the second stage and optimized the process parameters. The optimal working condition was as follows: 3.8 A of discharge current, 10 µs of discharge duration, 24 µs of discharge interval, 20 V of discharge voltage, and 17 N of wire tension. At optimal working condition, the metal removal rate, power consumption, surface roughness, and kerf width are found as 19.72 mm3/min, 49 W, 0.7 µm, and 351 µm, respectively. Moreover, the HTLBO took less time in optimization when compared with conventional TLBO.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Vignan’s Foundation for Science, Technology and Research, Vadlamudi, Guntur, Andhra Pradesh, 522213, India

    Kaki Venkatarao & Lam Suvarna Raju

  2. Department of Mechanical Engineering, Annamacharya Institute of Technology & Sciences, Tirupati, 517520, India

    Malla Chaitanya Reddy

  3. Department of Mining, College of Engineering and Technology, Bule Hora University, 144 Oromia, Bule Hora, Ethiopia

    Yekula Prasanna Kumar

  4. Aditya Institute of Technology and Management, Tekkali, Andhra Pradesh, 532201, India

    Bonula Rama Rao & Duppala Azad

Authors
  1. Kaki Venkatarao
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  2. Malla Chaitanya Reddy
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  3. Yekula Prasanna Kumar
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  4. Lam Suvarna Raju
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  5. Bonula Rama Rao
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  6. Duppala Azad
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Contributions

Dr. K Venkata Rao has supervised the experimentation and involved in optimization and manuscript preparation. Dr. M Chaitanya Reddy conducted experimentation and involved in analysis and manuscript preparation. Dr. Y Prasanna Kumar involved in optimization and analysis of experimental results. Dr. L Suvarna Raju prepared experimental plan and involved in analysis of experimental results and manuscript preparation. Dr. Bonula Rama Rao involved in the revision of manuscript and improved quality of the manuscript. Dr. Duppala Azad also involved in the revision of manuscript and improved quality of the manuscript.

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Correspondence to Yekula Prasanna Kumar.

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Venkatarao, K., Reddy, M.C., Kumar, Y.P. et al. Multi-response optimization in WEDM process of Al–Si alloy using TLBO-graph theory algorithm towards sustainability. Int J Adv Manuf Technol 126, 3679–3694 (2023). https://doi.org/10.1007/s00170-023-11355-8

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  • DOI: https://doi.org/10.1007/s00170-023-11355-8

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