Prediction and optimization of tool wear rate during electric discharge machining of Al/Cu/Ni alloy using adaptive neuro-fuzzy inference system

Aluminum (Al)-copper (Cu)-nickel (Ni) alloy is a versatile material with lightweight and excellent strength. It also possesses properties such as superior corrosion resistance, fatigue strength. These alloys are essential in sectors viz. automobile, aerospace, defense, aerospace, etc. In this research work, the authors have presented the prediction and analysis of tool wear rate (TWR). The impact of electrical discharge machining (EDM) on process parameters viz. input current (IP), pulse on time (TON), pulse off time (TOFF)/for Al/Cu/Ni alloy with the composition 91/4/5 and 87/8/5 (weight %) is analyzed. Taguchi's L(18) (2(1)∗3(3)) mixed plan is employed to plan the experimentation. A mathematical model develops to correlate these process parameters. A soft computing technique known as an adaptive neuro-fuzzy inference system (ANFIS) utilizes to predict TWR. Taguchi analysis reveals that input current is the most influencing parameter followed by pulse on time. TWR decreases with a decrease in the amount of Aluminium. It increases in the amount of copper in the alloy. TWR firstly decreases with an increase in pulse on time and then starts to grow after the median value of 25 micro-sec. The confirmation experiments have conducted using optimum process parameters to validate the obtained results. The experimental finding shows the superior capability of ANFIS to predict the TWR with acceptable accuracy. The optimized TWR obtained was 0.1238 mm(3)/min based on the optimal settings of input parameters.