Parametric Optimization of WEDM Parameters on AISI D2 Steel for Surface Roughness and Material Removal Rate using Taguchi Method

The performance of the WEDM machining process mainly depends upon the suitable selection of the appropriate machining variables. Optimization is one of the techniques used in manufacturing sectors to arrive for the best manufacturing conditions, for improving productivity of the system. As there are many process variables involved in the WEDM machining process, it is difficult to choose a proper set of combination of these process variables in order to maximize material removal rate and to minimize tool wear and surface roughness. The objective of the this research work is to evaluate the effects of process variables like pulse on time, pulse off time, peak current, servo voltage and wire feed on Material Removal Rate (MRR), Surface Roughness(SR). The design of experiments has been done using Taguchi's orthogonal array L27 (35). Each experiment was conducted under different conditions of input parameters as per the L27 array and was analyzed using MINITAB and Design Expert tools. The present work also aims to develop suitable mathematical models for correlating the inter-relationships of various WEDM machining parameters and Performance parameters of machining on AISI D2 steel material using regression analysis.