Parametric study along with selection of optimal solutions in dry wire cut machining of cemented tungsten carbide (WC-Co)

This work deals with parametric study of dry wire EDM (WEDM) process of cemented tungsten carbide. Experiments have been conducted using air as dielectric medium to investigate effects of pulse on time, pulse off time, gap set voltage, discharge current and wire tension on cutting velocity (CV) surface roughness (SR) and oversize (OS). Firstly, a series of exploratory experiments were carried out to identify appropriate gas and its pressure. Afterward, preliminary experiments were conducted to investigate effects of process parameters on dry WEDM characteristics and find appropriate ranges for each factor. Then a central composite rotatable method was employed to design experiments based on response surface methodology (RSM). Empirical models were developed to create relationships between process factors and responses by considering to analysis of variances (ANOVA). To increase the predictability of the process, intelligent models have been developed based on back-propagation neural network (BPNN) and accuracy of these models was compared with mathematical models based on root mean square error (RMSE) and prediction error percent (PEP). In order to select optimal solutions in the cases of single-objective and multi-objectives optimization problems, optimization includes two main approaches. First approach was based on mathematical model and desirability function. Also second approach was designed based on neural network and particle swarm optimization. These approaches were applied in both cases of single-objective and multi-objectives optimization problems and their results were compared with together. Results indicated that selection of air at inlet pressure of 1.5 bar is really appropriate for conducting experiments of next stages. Also, the BPNN creates more accurate prediction rather than mathematical model. Moreover, the BPNN-PSO approach was more efficient in optimization of process rather than mathematical model-desirability function in respect with validation tests.