Optimization in wire-cut EDM of Nimonic-80A using Taguchi's approach and utility concept

In the present study a multi response optimization method using utility concept is proposed for wire electrical discharge machining (WEDM) of Nimonic-80A alloy. The machining characteristics that are being investigated are material removal rate (MRR) and surface roughness (SR) along with surface topography of the machined surface. The study makes use of experimentation planned and executed as per Taguchi's robust design methodology. The Investigation indicated that material removal rate and surface roughness increases with increase in pulse-on time and decreases with increase in pulse-off time. Significant interactions have been found between pulse-on time (Ton) and pulse-off time (Toff), pulse-on time (Ton) and peak current (IP), pulse-off time (Toff) and peak current (IP) for material removal rate; and pulse-on time (Ton) and peak current (IP) for surface roughness. Multi-response optimization with utility concept provides the collective optimization of both responses for improving the mean of the process.