Machinability studies on wire electrical discharge machining of Nickel alloys using multiple regression analysis

Abstract

Wire Electrical Discharge Machining (WEDM) is most advanced method of machining conceived from the concept of spark erosion machining. Unconventional method of material removal processes have been developed to evade the difficulties in making of complex shapes in any electrically conductive work material with the help of traditional machining methods. Decision-making is progressively important in manufacturing domain due to its need for manufacturing components with quality and high precision. Stellite6 is difficult to machine and expansively used in wear surroundings where its low friction coefficient minimizes the danger of seizing and galling. The present work details the development of multiple regression equations for predicting the desired performance features in Wire EDM of Stellite material. Pulse On Time (μs), Pulse Off Time (μs) and peak current are selected as input variables and the material removal rate (MRR) is opted as performance characteristics in this present experimentation. The experimental runs are planned by Taguchi’s design approach and Taguchi’s single objective optimization technique was employed for attaining the best possible process parameters combination for obtaining better machining performance. Multiple regression analysis has been applied for developing empirical relationship among the process parameters. The developed regression equations are further used for prediction and comparison with the actual experimental results. The comparative results shows that the values predicted are closer with the experimental outcomes. The outcome attained from this exploration will be a wide-ranging support to the manufacturers for enhancing the rate of production and quality of products made with an assistance of WEDM process.