Prediction of Machining Characteristics and Machining Performance for Grade 2 Titanium Material in a Wire Electric Discharge Machine Using Group Method of Data Handling and Artificial Neural Network

The present research focuses on the machining of grade 2 titanium material using the Wire Electric Discharge Machining (WEDM) process by means of L₁₆ Orthogonal Array (OA). This study investigates numerous process parameters, including pulse on time, current, pulse off time, voltage, bed speed and flush rate. The voltage and flush rate were kept constant throughout the experiment, while the other four parameters were varied for the machining process. In this study, a 0.18 mm molybdenum wire was utilized as the electrode material. Initially, this research aimed to optimize the process parameters to discern their impact on machining characteristics (Surface Roughness and Electrode Wear) as well as on machining performance (Acoustic Emission Signals). Subsequently, simpler functional relationship plots were generated between these parameters to recognize the potential information about the machining characteristics and machining performance. The straightforward approach lacks the capability to furnish information regarding the condition of the material (Surface Roughness), the tool (Electrode Wear) and the signals (Acoustic Emission). Hence, to estimate the experimental values the numerical tools viz., Group Method of Data Handling (GMDH) and Artificial Neural Network (ANN) were used. Upon comparing the predictive performance of ANN and GMDH, it became evident that the ANN’s predictions using 70% of the data for training displayed a higher correlation with the experimental values compared to the GMDH.