Optimization of Machining Parameters in WEDM of AISI D3 Steel Using Taguchi Technique

Wire Electric Discharge Machining (WEDM) is a non-traditional process of material from conductive material to produce parts with intricate shape and profiles. Machine tool industry has made exponential growth in its manufacturing capabilities in last decade but still machine tools are not utilized at their full potential. In the present work, an attempt has been made to optimize the machining conditions for surface roughness based on (L9 Orthogonal Array) Taguchi methodology. Experiments were carried out under varying pulse-on-time, pulse-off-time, peak current, and wire feed. An orthogonal array, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) were employed to the study the surface roughness in the WEDM of AISI D3 Steel. It was observed that the discharge current was the most influential factors on the surface roughness. To validate the study, confirmation experiment has been carried out at optimum set of parameters and predicted results have been found to be in good agreement with experimental findings.