LAUSR

Wire-cut EDM (WEDM) is an important modern manufacturing technique largely used to process electrically conductive materials. Ti–6Al–4V alloy finds extensive applications in diverse engineering domain. This paper discusses estimation of power consumption (PC) as environmental aspect and its minimization using teaching learning-based optimization (TLBO) methodology for sustainable WEDM of Ti–6Al–4V alloy. A new fitness curve fitting methodology is presented to achieve global minima. Taguchi L 16 OA was adapted to conduct WEDM experiments. PC at optimal cutting conditions showed 11.21% improvement. The novel approach resulted in U-shaped fitness curve in the optimal search space. Pulse off time (43.26%) and current (31.24%) are found as the most significant process parameters influencing PC. Parametric variation of PC and surface morphology is also studied. Optimization result using TLBO algorithm is found consistent and converged quicker taking least computational time and effort.