Article

Journal of Mechanical Science and Technology

, Volume 27, Issue 7, pp 2133-2141

Parametric optimization for surface roughness, kerf and MRR in wire electrical discharge machining (WEDM) using Taguchi design of experiment

  • Adeel IkramAffiliated withFaculty of Engineering & Technology, University of Gujrat Email author 
  • , Nadeem Ahmad MuftiAffiliated withDepartment of Industrial & Manufacturing Engineering, University of Engineering & Technology
  • , Muhammad Qaiser SaleemAffiliated withDepartment of Industrial & Manufacturing Engineering, University of Engineering & Technology
  • , Ahmed Raza KhanAffiliated withDepartment of Industrial & Manufacturing Engineering, Rachna College of Engineering & Technology

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Abstract

This paper reports the effect and optimization of eight control factors on material removal rate (MRR), surface roughness and kerf in wire electrical discharge machining (WEDM) process for tool steel D2. The experimentation is performed under different cutting conditions of wire feed velocity, dielectric pressure, pulse on-time, pulse off-time, open voltage, wire tension and servo voltage by varying the material thickness. Taguchi’s L18 orthogonal array is employed for experimental design. Analysis of variance (ANOVA) and signal-tonoise (S/N) ratio are used as statistical analyses to identify the significant control factors and to achieve optimum levels respectively. Additionally, linear regression and additive models are developed for surface roughness, kerf and material removal rate (MRR). Results of the confirmatory experiments are found to be in good agreement with those predicted. It has been found that pulse on-time is the most significant factor affecting the surface roughness, kerf and material removal rate.

Keywords

Kerf MRR Surface roughness Taguchi method Wire-EDM