Some investigations into machining of AISI D2 tool steel using wire electro discharge machining (WEDM) process

Abstract

This paper reports on an experimental study performed in order to optimize the wire electro discharge machining (WEDM) process parameters namely peak current (IP), pulse-on-time (Ton), wire tension (WT) and wire feed rate (WF) to maximize the material removal rate (MRR) and minimize the surface roughness (SR). This study utilizes multiple regression analysis to predict model and find the optimal parameter settings for cutting of AISI D2 tool steel by WEDM using plain brass wire of 0.25 mm diameter. Experiments were designed and planned as per Taguchi’s L9 (34) orthogonal array. Each runs were repeated twice and the mean responses have been considered. Analysis of variance (ANOVA) technique was used to determine the most important WEDM process parameters which significantly influence the material removal rate and surface roughness. It has been observed that surface roughness and material removal rate increases with increase in pulse-on-time and peak current whereas decreases with increase in wire tension and wire feed rate. Finally, it was concluded that peak current and pulse-on-time are most significant parameters which affects material removal rate and surface roughness respectively than other parameters considered in this study. Wire tension and wire feed rate have less influence on surface finish and material removal rate. Furthermore, surface roughness and material removal rate slightly decreases with increase in wire tension and wire feed rate.