Optimization of Process Parameters in W-EDM with HCHCR by Using Taguchi Optimization Technique and Grey Relational Analysis

Abstract

AbstractWire-cut electrical discharge machine (W-EDM) is a precision machining approach that produces geometrically complex structures with a high level of accuracy and a smooth surface finish. The W-EDM is an unconventional machining technique which is also characterized by longer machining times which affect the machining characteristics. As it is modified process, still research is going on to find out optimum settings of pulse parameters which will improve the machining rates. HCHCR (High Carbon High Chromium) contains the minimum of 1.5–2.35% carbon and 12% of chromium widely used in thread rolling dies, hobs, and extrusion tools and therefore chosen as work piece material. In this present work, the HCHCR is taken as work piece, 0.25 mm diameter of brass wire used as the tool. For the experimentation, L-16 orthogonal array (OA) has been applied. The I/P process parameters chosen for optimizations are pulse on time (Ton), pulse off time (Toff), Servo Voltage (SV), Wire Feed (WF), Material Removal Rate (MRR), Surface Roughness (SR), and Kerf width (KW) as the performance characteristics. In the present study, Grey Relational Analysis (GRA) and Taguchi optimization method and ANOVA are used to analyze the results. The present work focuses on to develop and simulate an optimization model using Taguchi, GRA, and ANOVA for attaining higher MRR, lower SR, and KW. Hence, this work deals with the multi-objective optimization of process parameters in W-EDM with HCHCR as work material.KeywordsWire-EDMTaguchi optimization methodGRAHCHCR