Process parameters optimization and performance analysis of micro-complex geometry machining on Ti6Al4V

The aeronautical industry relies on high-performance equipment that demands materials with exceptional engineering attributes, such as the Ti6Al4V alloy. However, the complexity of the parts used in these applications presents challenges related to stack-up tolerances during assembly. Therefore, conventional machining processes are not economically viable due to their two-step nature solution (machining and surface treatment) and their inability to achieve the required accuracy level, particularly given the alloy’s hard-to-cut nature. In this matter, wire electric discharge machining (WEDM) emerges as an attractive alternative for fabricating complex geometries. This research focuses on evaluating the potential of the WEDM process for machining micro-complex profiles. A comprehensive range of process parameters, including servo voltage (V s ), pulse on time (T on ), pulse off time (T off ), and wire speed (W s ), are studied using a Taguchi-based design of experiments. The results are analyzed through parametric significance analysis, parametric control analysis, surface morphological analysis using scanning electron microscopy, and modified layer analysis. Additionally, both mono-objective and multi-objective process optimization techniques are employed to achieve superior accuracy and speed. The findings indicate that T on and W s have the most significant influence on both cutting speed and spark gap, whereas V s and T off play a crucial role in determining the accuracy index. In addition, adequate flushing, reduced wire speed (economically viable), and stability of the spark are recommended to attain a lower spark gap and higher accuracy. The confirmatory experiments show that the optimal parametric conditions of V s = 60 V, T off = 30 μs, T on = 8 μs, and W s = 6 mm/s provide the highest speed of 3.4 mm/min, minimum spark gap of 0.344 mm, and accuracy index of 98.72%. The findings will contribute to enhancing manufacturing efficiency, precision, and cost-effectiveness in the aeronautical industry, meeting the demand for high-quality components with tight tolerances.