This study discusses the machinability analysis of copper (Cu) electrodes that are manufactured through direct metal laser sintering (DMLS), an additive manufacturing (AM) process to produce parts that are conductive. This investigation gives the impact of wire electrical machining parameters like peak current, pulse on time and gap voltage over the material removal rate (MRR), surface roughness (SR), and kerf width (KW). The wire electrical discharge machining (WEDM) process is employed on DMLS Cu electrode using Taguchi's L27 orthogonal array design. Due to a high peak current, gap voltage, and pulse on time, a high heat energy and sparking frequency is produced, thereby it increases the MRR of DMLS Cu electrodes in WEDM process. Adversely at high peak current, high thermal loading occurs and thus discharge energy increases, leading to an increased KW. This KW first rises to a certain extent and then drops down as the gap voltage is increase. In order to achieve greater MRR, lower KW, and enhanced SR, grey relational analysis (GRA) was used to establish the ideal combination of parameters: gap voltage = 40 V, peak current = 5 A, and pulse on-time = 16 µs. Furthermore, an impressive 99.85% accuracy rate was achieved in predicting WEDM responses using a 3-27-3 artificial neural network (ANN). All things considered, this work gives insightful information about the machinability of DMLS Cu electrodes and suggests improvements for the EDM procedure.
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