Parametric Optimization During Wire EDM Taper Cutting on AISI D2 Steel Using Desirability Function

Abstract

Wire electrical discharge machining (WEDM) has become very popular non-traditional process of machining. Taper cut WEDM involves making surfaces of sloping, this is essential in machining tools with angles included. AISI D2 steel with Mo and Cr has a variety of applications in engineering. This paper aims to study the effect of taper angle, wire feed and wire tension on the responses such as cutting time, angular error and surface roughness and also find the optimum values of each variable that achieve optimum cutting conditions. Central Composite design (CCD) of response surface methodology was used to design the experiments and five values of each of the three variables are taken. In order to combine the responses and the parameters in one model regression model has been generated. For each response separate analysis of variance (ANOVA) was calculated and the optimization was performed using desirability function. Results show that the most significant parameter is taper angle and the optimized parameter levels of the machining are taper angle 6°, wire feed 5.624 mm/min and wire tension 7.886 g respectively.