PARAMETRIC OPTIMIZATION OF WIRE ELECTRIC DISCHARGE MACHINING ON D2 DIE STEEL USING TAGUCHI’S METHODOLOGY

Abstract

The aim of this project is to optimize the WEDM combination parameters in order to get the optimum material removal rate (MRR) and surface roughness (SR) on material of D2 Die Steel. This project begins with a preliminary design that proposes on the design factors which have possibility to affect the responses. In this project we are concentrating on only five parameters for experiment which are called control parameter. That are peak current (IP), time on (T ON), time off (T OFF), wire feed (WF) and wire tension (WT). Remaining all parameters which are called fixed parameter and their optimum values are taken constant throughout the experiments. It starts with application of Design of Experiment (DOE) on Taguchi Method that applying L-18 (61,34) from the Orthogonal Array (OA). Results which have been obtained from the 18 trials of experiments are analyzed to get the optimum condition and predicted value. Also an analysis is done on multi-quality by MINITAB 15 software to get a best combination factors for all combination of the responses. The optimal values obtained using the multi-quality optimization model has been validated by confirmation experiments. This dissertation work present an investigation on the effect and optimization of the machining parameter for material removal rate and surface roughness, in wire electric discharge machining (WEDM) of D2 die steel.