Parametric Optimization in Wire Electrical Discharge Machining of Titanium Alloy Using Response Surface Methodology

Abstract

Wire Electrical Discharge Machining (WEDM) is extensively used for machining of complex shapes in the field of die and mould making, medical, aerospace and automobile industries for machining of too hard materials. Improper selection of WEDM process parameters setting can affect the machining efficiency and surface roughness due to arcing phenomenon that lead by electrical discharge. Present study has been made to optimize the process parameters during machining of titanium (Ti-6Al-4V) alloy by WEDM using response surface methodology (RSM). Five input process parameters of WEDM namely Pulse on time, pulse off time, servo voltage, input power and wire tensionwere chosen as variables to study the process performance in terms of kerf width, material removal rate (MRR), surface roughness. The analysis of variance (ANOVA) was carried out to study the effect of process parameters on process performance and mathematical models havebeen developed for response parameters. Properties of the machined surface have been examined by the scanning electron microscope (SEM).The experimental results revealthat the kerf width increases as the pulse on time, input power, server voltage and wire tension increases and the MRR increases as the pulse on time and input powerincreases. It is observed that as the pulse on timeand input power increases, the surface roughness also increases. Further it is observed that as and when the wire tension and servo voltage increases the surface roughness decreases and it improves the quality of machined surface.