OPTIMIZATION OF PROCESS PARAMETERS FOR OPTIMUM METAL REMOVAL RATE IN WIRE EDM OF AISI D2 TOOL STEEL USING TAGUCHI METHOD

MECHANICAL ENGINEERING

Wire cut Electrical discharge machining is one of the most widely used un-conventional machining process for producing die and punches for blanking. Wire EDM has capacity to produce the complex shapes and profiles with highest accuracy and precision. It can machine any electrically conducting material irrespective of its hardness. However, the performance of WEDM process depends upon the various process parameters selected as well as material of the work-piece to be machined. A lot of research work has been reported regarding the optimization of process parameters used in WEDM process but to get higher metal removal rate with good surface finish on machined surface is still a difficult task to researchers. In the present work, cold worked D2 tool steel bar and heat treated D2 tool steel bars of 13mm diameters were machined by using 0.25mm diameter brass wire electrode with same process parameter. Along with the heat treatment the influence of various input process parameters such as (Ton, Toff, Ip, Sv) on the response characteristics (MRR ) was investigated by using Taguchi L9 orthogonal array. Signal to noise ratio and ANOVA is also applied in order to determine the optimum process parameters for getting optimum metal removal rate. From the predicted optimum range of process parameters and confirmation experiments it’s found that, for heat treated material metal removal rate increased as compared to cold worked D2 Tool steel material.

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