A Study and Investigation on MRR in Wire Electrical Discharge Machining using Molybdenum Wire

Wire electrical discharge machining process is a highly complex, time varying & stochastic process. The process output is affected by large no of input variables. Therefore a suitable selection of input variables for the wire electrical discharge machining (WEDM) process relies heavily on the operators technology & experience because of their numerous & diverse range. WEDM is extensively used in machining of conductive materials when precision is of prime importance. Rough cutting operation in wire EDM is treated as challenging one because improvement of more than one performance measures viz. Metal removal rate(MRR), surface finish & cutting width (kerf), Dimensional derivation, Cutting Speed, Machining Time are sought to obtain precision work. In this work an approach to determine parameters setting is proposed. Using taguchi‟s parameter design , significant machining parameters affecting using Copper, Brass, Tugstan carbide and aluminum wire electrode, the performance measures are identified as pulse peak current , pulse on time, pulse off time, Flushing Pressure, Wire Speed, Wire tension and duty factor . The effect of each control factor on the performance measure is studied individually using the plots of signal to noise ratio, Grey relation Analysis and ANN and ANOVA Technique, The study demonstrates that the WEDM process parameters can be adjusted so as to achieve better metal removal rate, surface finish, electrode wear rate.