Process Parameter Optimization in Electrical Discharge Machining

Abstract

Electrical discharge machining is a proved alternative process used for machining of intricate and complex shapes from the work piece. It is a nonconventional machining method. In this process electrical energy is used to cut the material to desired shape and size. Ef orts are made to utilize the whole energy by applying it at the exact point where the operation needs to be carried out. Surface roughness and kerf width are of vital in the machining processes. To optimize cutting parameters in Wire EDM for D3 steel material this paper uses the Grey relational theory and Taguchi optimization technique. The best surface finish is achieved by minimum kerf width. In the machining process brass wire of 0.25 mm diameter is used as a tool and Pulse ON, pulse OFF time with servo voltage use as a input parameter. Wire tension, dielectric fluid, wire speed are fixed parameters. Contact type surf coder and video measuring coder machine is used for measurement of surface roughness and kerf width. Optimal value is calculated by grey relational analysis and taguchi method. Moreover, the analysis of variance (ANOVA) is used to identify the most important factor. By applying Taguchi and Grey relational analysis we get optimum values of Material remal rate (MRR), Kerf Width and surface roughness (SR).