Parametric optimization of wire electrical discharge machining (WEDM) process using taguchi method

Abstract

Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. Parts having sharp edges that pose difficulties to be machined by the main stream machining processes can be easily machined by WEDM process. Technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal with a difference that spark is generated at wire and work piece gap. Since the introduction of the process, WEDM has evolved as a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish. This paper outlines the development of a model and its application to optimize WEDM machining parameters. Experiments are conducted to test the model and satisfactory results are obtained. The methodology described here is expected to be highly beneficial to manufacturing industries, and also other areas such as aerospace, automobile and tool making industries

Optimization of Wire-EDM Process Parameters on Machining Die Steel DC53 using Taguchi Method with Grey Relational Analysis – A Review

“…The methodology described here is expected to be highly beneficial to manufacturing industries, and also other areas such as aerospace, automobile and tool making industries. [8] Kanlayasiri and Boonmung [2007] presented an investigation of the effects of machining variables on the surface roughness of WEDMed DC53 die steel. In this study, the machining variables investigated were pulse-peak current, pulse-on time, pulse-off time, and wire tension.…”

“Research Work for Optimization and Effect of WEDM Cutting Process Parameters on Performance Measures- a Literature Review”

“…Robofil 100 high precision five axis CNC WEDM was elected for performing experiments. Optimized machining parameters for maximum MRR and SF in WEDM were determined through Taguchi method [32].A. Hasçalyket.…”

Multi-objective optimization in WEDM of D3 tool steel using integrated approach of Taguchi method & Grey relational analysis

“…They concluded that the servo voltages have significant influence on the MRR. Mahapatra and Patnaik (2006) established the relationship between various process parameters and responses using non-linear regression analysis and then employed genetic algorithm to optimize the WEDM process. Singh and Garg (2009) machined hot die steel (H-11) on WEDM.…”