, Volume 27, Issue 7, pp 2133-2141
Date: 17 Jul 2013

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

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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.

Recommended by Associate Editor Haedo Jeong
Adeel Ikram is serving as Lecturer in Faculty of Engineering and Technology, University of Gujrat, Gujrat, Pakistan. He received his B.Sc. in Industrial and Manufacturing Engineering and M.Sc. in Manufacturing Engineering from department of Industrial and Manufacturing Engineering, University of Engineering and Technology (UET), Lahore, Pakistan. His research interests include Conventional and Non-conventional Machining Processes, Advanced Materials Processing, Designing and Analysis of mechanical components.
Nadeem Ahmad Mufti is Professor and Chair, Department of Industrial and Manufacturing Engineering, University of Engineering & Technology (UET), Lahore, Pakistan. He got his B.Sc. in Mechanical Engineering and M.Sc. in Production Engineering from UET Lahore. Later, he received another M.Sc. (Manufacturing Engineering & Management) and Ph.D. (Manufacturing & Mechanical Engineering) from University of Birmingham, UK. His research interests include Conventional and Non-conventional Machining, Metal Forming, Operations Management, Human Factor Engineering and Project Management.
Muhammad Qaiser Saleem is currently associated with Department of Industrial & Manufacturing Engineering, University of Engineering & Technology (UET), Lahore, Pakistan as Assistant Professor. He is an alumnus of the Fulbright Program, who has earned his Ph.D. in Manufacturing Engineering from Worcester Polytechnic Institute (WPI), Worcester, MA, USA whereas his Bachelors in Mechanical Engineering and Masters in Engineering Management are from UET, Lahore, Pakistan. He is an academician with more than 10 years’ experience in teaching, research and administrative assignments. His research interests include Manufacturing Processes and locally constrained Engineering Management issues.
Ahmed Raza Khan is working as Assistant Professor in Department of Industrial & Manufacturing Engineering, Rachna College of Engineering & Technology, Gujranwala (a constituent college of UET, Lahore) Pakistan. He obtained his B.Sc. (honors) in Industrial & Manufacturing Engineering and M.Sc. in Manufacturing Engineering from University of Engineering and Technology, Lahore, Pakistan. His research interests are Cutting Tool Technology, Conventional, Non-conventional and High Speed Machining Processes.