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06 Application of Taguchi Method For Determining Optimum Surfaces

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06 Application of Taguchi Method For Determining Optimum Surfaces

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hcquan.sdh222
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com

ScienceDirect
Procedia Engineering 97 (2014) 1565 – 1576

12th GLOBAL CONGRESS ON MANUFACTURING AND MANAGEMENT, GCMM 2014

Application of Taguchi Method for Determining Optimum Surface


Roughness in Wire Electric Discharge Machining of P/M Cold
Worked Tool Steel (Vanadis-4E)
D.Sudhakaraa*,G.Prasanthib
a
Associate Professor,Dept. of Mechancal,SISTK,Puttur-517583,AndraPradesh,India
b
Professor, Dept. of Mechancal,JNTUACE,Anantapur-515002,Andrapradesh,India

Abstract

This paper introduced on advancing the wire electrical discharge machine (WEDM) process parameters for the normal surface
roughness (Ra) acquired in machining of VANADIS 4e (Powder metallurgical cold worked Tool steel). The Machining analyses
were performed at WEDM machine utilizing 0.25 mm wire as electrode material on p/m cold worked tool steel. Taguchi L 27
orthogonal array (OA) was utilized to outline of trial. Ideal methodology parameters were resolved utilizing the signal- to- noice
(S/N) proportion which was computed for Ra as per ''the- smaller- the-better'' approach. The methodology parameters of WEDM
procedure were pulse on time (ON), pulse off time (OFF), servo voltage (SV), peak current (IP), wire tension (WT) and water
pressure (WP). The impacts of the methodology parameters on surface roughness were assessed by the examination of change
(ANOVA). The most essential associations, that impact surface roughness of machined surfaces, are between the pulse on time
(ON) and pulse on time(ON), pulse off time(OFF) and Peak current(IP), and between pulse on time(on) and Peak current(IP).
The ideal estimation of surface roughness is anticipated at the ideal levels of noteworthy as Pulse on time (A1), pulse off time
(B3), peak current (C3) and spark gap set voltage (D1) and wire tension (E3).

© 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
© 2014 The Authors. Published by Elsevier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selectionand
Selection and peer-review
peer-review underunder responsibility
responsibility of the Organizing
of the Organizing Committee Committee
of GCMM 2014of GCMM 2014.

Keywords: wire electrical discharge machine; optimization; Surface roughness; Taguchi design; ANOVA

1. Introduction
Non traditional machining methods are dynamically used to fabricate great mechanical segments. In non traditional
__________

* Corresponding author. Tel.: +9-988-592-8923; fax: +0-000-000-0000 .


E-mail address: [email protected]

1877-7058 © 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014
doi:10.1016/j.proeng.2014.12.440
1566 D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576

machining methodology wire electrical discharge machine (WEDM) is a thermo electrical machining process in
which the material is expelled from work piece by series of electrical sparks between wire electrode and work piece.
The vitality substance of a single spark discharge is communicated as a result of pulse on time and peak current.
Vitality contained in a minor sparkle release evacuates as part of work piece material. Extensive number of such
time separated minor releases between work piece and wire electrode causes the electro disintegration of the work
piece material. Al, brass, zinc covered metal or copper wires are generally used as electrode material. The distance
across of the wire electrode is of 0.25mm to 0.50mm measurement .Wire electrical discharge machine will be
machine instrument to create parts of perplexing and multifaceted segments in the field of tool and die, aviation,
automobile, atomic, machine industry. In the present exploration study WEDM of VANADIS 4E (powder
metallurgical cold worked tool steel) has been considered. This material is considered for exploration work because
of its both high wear resistant and ductility. VANADIS 4E is a chromium-molybdenum-vanadium alloyed steel
which is described by extremely ductility, high abrasive- adhesive wear and compressive strength, great
dimensional stability amid heat treatment in service, great machine capacity and drudgery capability. The primary
synthetic creation of VANADIS 4e is C-1.4%, Si-0.4%, mn-0.4%, Cr-4.7%, Mo-3.5% and Va-3.5% and the offset is
Fe. The density of VANADIS 4E is 7700kg/m3.
2. Literature review
Speeding and Wang (1997) Performed trial study on AISI 420 steel to streamline the strategy parameters in combos
by displaying the technique exploitation ANN and described the WEDM machined surface by arrangement system.
M.i.gokler et.al. (2000) led investigates Sodic Mark XI A500 EDW WEDM as machine and 1040, 2379 and 2378
steels as work piece materials with a specific end goal to research the consequence of cutting and counterbalance
parameters on surface roughness in WEDM process. From the results it totally was finished that, the counterbalance
parameters doesn't have an impact on the surface roughness and same result with cutting parameters .If the thickness
of the work piece will build, the average feed rate diminishes. Tusan et.al. (2003) utilized AISI 4140 steel as work
piece material and Sodic A320/Ex21 WEDM as machine instrument directed tests to audit the varieties of cutting
parameters with pulse on time, open circuit voltage, wire velocity and dielectric fluid pressure. The reactions
thought-about amid this study were surface roughness and cutting rate. From the results it totally was discovered
that the cutting speed and surface roughness were will expand with increment in pulse on time, open circuit voltage
and dielectric fluid pressure. Numerical connections between cutting parameters and cutting exhibitions were
produced by regression analysis method. The created model was utilized within evaluating execution attributes.
Taking into account Anova strategy, the open circuit voltage, pulse duration of time and wire pace were more viable
on cutting velocity. While the dielectric liquid weight was immaterial. If there should be an occurrence of surface
roughness, the open circuit voltage and pulse duration of time were more successful, wherever as dielectric fluid
pressure and wire velocity were ineffectual. Sarkar et.al. (2005) directed probes Electra SUPERCUT 734, SERIES-
200 CNC WEDM machine exploitation γ-titanium Aluminide composite as work piece material so made a model
they anticipate the cutting speed , surface finish and dimensional deviation as the work of diverse WEDM
parameters. Each one surface roughness and dimensional deviation is free of pulse off time. So pulse off time could
be fluctuated according to necessity to achieve the higher stability and correctness while not influencing the
dimensional deviation and surface finish respectably. They decided the ideal technique parameters by applying
unnatural optimization procedure amid which one execution trademark was streamlined considering diverse as
stipulations. Taweel et.al.(2005) utilizes AN ELEKTTA Maxicut434 CNC WEDM as machine device and
INCONEL-601 as work piece , created a scientific model for associating interrelationship of WEDM system
parameters like peak current, duty factor, wire tension, water pressure and reactions mr, wr and sr utilizes RSM
approach.Mahapatraet.al. (2006) allocated test studies on Robofil100 WEDM with D2-Tool Steel. They
acknowledge relationship between control components and reactions like metal removal rate and surface finish by
non linear regression analysis. GA was utilized to improve the WEDM system with various destinations.
D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576 1567

3. Design & analysis of experiments

Dr. Taguchi has developed a method predicated on "ORTHOGONAL ARRAY" experiments which gives much
reduced " variance " for the experiment with " optimum settings " of control parameters. Thus the espousement of
Design of Experiments with optimization of control parameters to obtain BEST results is achieved in the Taguchi
Method. "Orthogonal Arrays" (OA) provide a set of well balanced (minimum) experiments and Dr. Taguchi's
Signal-to-Noise ratios (S/N), which are log functions of desired output, accommodate as objective functions for
optimization, avail in data analysis and presage of optimum results. Taguchi method is utilized in the industry to
decrement the product development period for the design and engenderment which withal decrease the costs and
increment the profit of the company. Taguchi method withal sanctions controlling the variations caused by the
uncontrollable factors which are not taken into consideration at conventional design of experiment. Taguchi
converts the objective function values to signal-to-noise (S/N) ratio for measure the performance characteristics of
the calibers of control factors against these factors. S/N ratio is defined as the desired signal ratio for the undesired
arbitrary noise value and shows the quality characteristics of the experimental data. There are three different
functions utilized which are kenned as the objective function and withal defined as S/N ratio: ‘‘the-larger-the-
better’’, ‘‘the-smaller-the-better’’ and ‘‘the-nominal-the-best’’. Besides, ANOVA is utilized to determine the
statistical paramountcy of the cutting parameters. The optimum cumulation of the cutting parameters is tenacious by
the avail of ANOVA and S/N ratios.
Lastly, substantiation experiments are done utilizing the optimum machining parameters which were found by
Taguchi optimization method and thereby validation of the optimization is tested. In this study, cutting parameters
are optimized for the average surface roughness (Ra) occurred in wire cut EDM machining. Pulse on time (ON),
pulse off time (OFF), spark gap set voltage (SV), peak current (IP), wire tension (WT) and water pressure (WP) are
culled as cutting parameters (variables). The parameter levels were culled within the intervals recommended by the
cutting implement manufacturer. L27 orthogonal array of Taguchi method was utilized in the design of experiment.
Variables and their calibers are given in Table 1. The-"smaller-the-better" performance characteristics for Ra were
applied in order to obtain the optimal cutting parameters. S/N ratio. The S/N ratios of six factors were calculated for
Ra. ANOVA was applied with 95% confidence level to determine the consequentiality level of the variables on Ra.
Optimization process predicated on the Taguchi method was performed by Minitab 15 software. Minitab is potent
software that solves many statistical quandaries with facileness. This software is frequently used performing
statistical analysis and quality amelioration in area of mathematics, statistics, economics, sports and engineering.

In the present study six parameters pulse on time, pulse off time, peak current, spark gap set voltage, wire tension
and water pressure were culled as input parameters during machining of work piece. The Experiments were
conducted with distilled water as di-electric fluid and its conductivity is 20S, Servo feed is 2150 m/min, wire feed as
8 m/min with a coated brass wire of 0.25 diameter as electrode. The six parameters were assigned values in 3 levels
predicated on trail experiments. The preliminary experiments were conducted to cull the range of values for
machining parameters.

Table 1: Process parameters their values and ranges

SNO PROCESS PARAMETERS SYMBOL UNITS LEVEL 1 LEVEL 2 LEVEL 3

1 Pulse On Time ON μsec 108 118 128


2 Pulse Off Time OFF μsec 47 55 63

3 Peak Current IP Amperes 11 13 15

4 Spark gap set voltage SV Volts 18 43 68

5 Wire Tension WT Grams 2 5 8


2
6 Water Pressure WP Kg/cm 8 11 14
1568 D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576

4. Experimental set up and preparation of specimens

The Vanadis 4E Implement steel plate of 100mm x 98mm x 24mm size is mounted on the ELECTRONICA
ULTIMA 1F WEDM machine implement (Figure 1) and specimens of 7mmx7mmx24mm size are cut. The close up
view of plate blank utilized for cutting the specimens is shown mounted on the WEDM machine (Figure 2). A set of
cut specimens is shown in Figures 3 and 4. Surface roughness quantification was done utilizing a portable stylus-
type profilometer (Taylor Hobson, Surtronic-3+) as shown in figure 5. The profilometer was set to a cut-off length
of 0.8 mm and 4mm valuation length. The least count of the profilometer is 0.01 micron.

Fig.1: Electronica Ultima 1F WEDM setup Fig.2: Work piece Mounted on WEDM

Fig.3. Pieces lying in vertical after WEDM Fig.4. Pieces lying in horizontal after WEDM
D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576 1569

Fig 5. Taylor-Hobson surface roughness Tester

5. Result analysis
The 27 experiments were conducted on the work piece as per L 27 orthogonal array in order to ascertain the effect of
machining parameters on surface roughness. The experimental data is shown in table 2. The average values of
cutting rate for each parameter level 1, 2 and 3 for raw data.

Table 2: Experimental Results for Surface roughness with cutting conditions and S/N ratio values
Trail ON OFF IP SV WT WP SURFACE ROUGHNESS (μm) S/N RATIO
No (μsec) (μsec) (Amps) (Volts) (Grms) (kg/cm2) R1 R2 R3
1 108 47 11 18 2 8 1.98 1.92 2.02 -5.90589
2 108 47 12 43 5 11 1.83 1.83 1.82 -5.23321
3 108 47 13 68 8 14 1.75 1.78 1.8 -4.9927
4 108 55 11 43 5 14 1.88 1.84 1.94 -5.51596
5 108 55 12 68 8 8 1.83 1.82 1.8 -5.18571
6 108 55 13 18 2 11 1.64 1.6 1.69 -4.31669
7 108 63 11 68 8 11 1.96 1.87 1.95 -5.69803
8 108 63 12 18 2 14 1.73 1.65 1.65 -4.49113
9 108 63 13 43 5 8 1.66 1.65 1.69 -4.43743
10 118 47 11 43 8 11 3.08 2.96 3.2 -9.77541
11 118 47 12 68 2 14 2.95 2.98 2.94 -9.41619
12 118 47 13 18 5 8 2.04 2.08 1.99 -6.17982
13 118 55 11 68 2 8 3.11 3.13 3.15 -9.911
14 118 55 12 18 5 11 1.95 1.98 1.98 -5.88955
15 118 55 13 43 8 14 2.27 2.29 2.24 -7.10811
16 118 63 11 18 5 14 2.23 2.26 2.17 -6.92829
17 118 63 12 43 8 8 2.48 2.37 2.49 -7.77364
18 118 63 13 68 2 11 2.18 2.21 2.3 -6.96837
19 128 47 11 68 5 14 3.58 3.47 3.75 -11.1305
20 128 47 12 18 8 8 2.43 2.41 2.4 -7.65246
21 128 47 13 43 2 11 3.25 3.23 3.28 -10.2467
22 128 55 11 18 8 11 2.68 2.74 2.65 -8.59589
23 128 55 12 43 2 14 3.11 3.21 2.97 -9.82227
1570 D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576

24 128 55 13 68 5 8 2.99 2.95 3.02 -9.50414


25 128 63 11 43 2 8 3.42 3.4 3.4 -10.6466
26 128 63 12 68 5 11 3.18 3.29 3.2 -10.1671
27 128 63 13 18 8 14 1.88 1.84 1.89 -5.43741

5.1 Effect of surface roughness


The surface roughness increases with increase in pulse on time and peak current and decreases with pulse of time,
spark gap set voltage and wire tension . This is because the discharge energy increases with pulse on time and peak
current and more sizably voluminous discharge energy engenders a more astronomically immense crater, causing a
more immensely colossal surface roughness value on the work piece. When the pulse of time decreases, the number
of discharges increases which causes poor surface finish. With increase in spark gap set voltage, the average
discharge gap gets widened leading to more preponderant surface precision due to stable machining. As the wire
tension increases, the fluctuation of wire gets reduced and it results in more preponderant surface finish on the
specimens. The effect of water pressure is not very consequential. It is observed from the figure6 and figure 7 that
there is remote interaction between pulse off time and peak current while there is impotent interaction between other
parameters in effecting surface roughness since the replications at different calibers of those parameters are virtually
parallel. The residuals plots do not show any quandary in the distribution of the data and the model postulations
(figure 8 and figure 9)

Fig. 6. Effects of Process Parameters Interactions on Surface roughness (Raw Data)


D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576 1571

Fig. 7. Effects of Process Parameters Interactions on Surface roughness (S/N Data)

Fig. 8. Residual Plots for Surface roughness (Raw Data)


1572 D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576

Fig.9:. Residual Plots for Surface roughness (S/N Data)

5.2 Selection of optimum levels


In order to study the paramountcy of the process parameters towards the surface roughness, ANOVA was
performed. It was found that water pressure is non paramountcy process parameter for surface roughness. Non
Paramountcy parameters were pooled and the pooled versions of ANOVA of the S/N data and raw data for surface
roughness are given in table 3 and table 4 respectively.
Table 3: Pooled Analysis of Variance for (S/N ratios)

Analysis of Variance for SN ratios


Source DF Seq SS Adj SS Adj MS F P
ON 2 80.027 80.027 40.0135 115.62 0.000
ON 2 80.027 80.027 40.0135 115.62 0.000
IP 2 12.438 12.438 6.2188 17.97 0.000
SV 2 20.173 20.173 10.0863 29.14 0.000
WT 2 5.312 5.312 2.6560 7.67 0.005
Residual Error 16 5.537 5.537 0.3461
Total 26 127.064
DF - degrees of freedom, SS - sum of squares, MS - mean squares(Variance), F-ratio of variance of a source to variance of error, P < 0.05 -
determines significance of a factor at 95% confidence level

Table 4: Pooled Analysis of Variance for Means (Raw data)

Analysis of Variance for Means


Source DF Seq SS Adj SS Adj MS F P
ON 2 6.0171 6.0171 3.00856 86.69 0.000
OFF 2 0.2881 0.2881 0.14407 4.15 0.035
IP 2 0.9838 0.9838 0.49190 14.17 0.000
SV 2 1.7316 1.7316 0.86582 24.95 0.000
WT 2 0.5395 0.5395 0.26974 7.77 0.004
Residual Error 16 0.5553 0.5553 0.03470
Total 26 10.1154
DF - degrees of freedom, SS - sum of squares, MS - mean squares(Variance), F-ratio of variance of a source to variance of error, P < 0.05 -
determines significance of a factor at 95% confidence level
D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576 1573

Table 5: Response Table for Signal to Noise Ratios

Response Table for Signal to Noise Ratios


Smaller is better
Level ON OFF IP SV WT
1 -5.086 -7.837 -8.234 -6.155 -7.969
2 -7.772 -7.317 -7.292 -7.840 -7.221
3 -9.245 -6.950 -6.577 -8.108 -6.913
Delta 4.158 0.887 1.657 1.953 1.056
Rank 1 5 3 2 4

Table 6: Response Table for Means

Response Table for Means

Level ON OFF IP SV WT

1 1.799 2.546 2.657 2.055 2.596

2 2.482 2.387 2.381 2.548 2.380

3 2.949 2.296 2.192 2.627 2.254


Delta 1.150 0.250 0.465 0.573 0.342

Rank 1 5 3 2 4

From that table it is observed that pulse on time, off time, peak current, spark gap set voltage and wire
tension has vigorously affecting the both mean and variation in the surface roughness values. The replication tables
(Tables 5 and 6) show the average of each replication characteristic (S/N data and raw data) for each level of each
factor. The Tables include ranks predicated on delta statistics, which compare the relative magnitude of effects. The
delta statistic is the highest minus the lowest average for each factor. Minitab assigns ranks predicated on delta
values; rank 1 to the highest delta value, rank 2 to the second highest, and so on. The ranks betoken the relative
paramountcy of each factor to the replication. The ranks and the delta values for sundry parameters show that pulse
on time has the greatest effect on surface roughness and is followed by spark gap set voltage, peak current, wire
tension and pulse off time in that order.
As surface roughness is the “lower the better‟ type quality characteristic, it can be optically discerned that
the first level of pulse on time (A1), third level of pulse off time (B3), third level of peak current (C3), first level of
spark gap set voltage (D3), and third level of wire tension (E3) result in minimum value of surface roughness. The
S/N ratio analysis withal suggests the same levels of the variables (A1, B3, C3, D3 and E3) as the best levels for
minimum SR in WEDM process.

5.3 Estimation of optimum response characteristics


In this section, the optimal values of the replication characteristics surface roughness along with their respective
confidence intervals have been prognosticated. The results of substantiation experiments are withal presented to
validate the optimal results. The optimal levels of the process parameters for the culled replication characteristics
have already been identified. The optimal value of each replication characteristic is soothsaid considering the effect
of the consequential parameters only. The average values of the replication characteristics obtained through the
attestation experiments must lie within the 95% confidence interval, CI CE equation . However, the average values of
1574 D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576

quality characteristics obtained from the substantiation experiments may or may not lie with in 95% confidence
interval, CIPOP (calculated for the mean of the population).

5.4 Surface roughness


The optimum value of surface roughness is predicted at the optimal levels of significant variables which
have already been selected as pulse on time (A1), pulse off time(B3), peak current (C3) and spark gap set voltage
(D3) and wire tension(E3) (Table 4). The estimated mean of the response characteristic surface roughness can be
determined (Kumar, 1993 and Roy, 1990) as:

+ + + + -4

where
= overall mean of cutting rate = (∑R1+∑R2+∑R3)/81 = 2.41 μm

= Average value of cutting rate at the first level of pulse on time = 1.799259 μm
= Average value of cutting rate at the third level of pulse off time =2.296296 μm
= Average value of cutting rate at the third level of peak current = 2.192222 μm
= Average value of cutting rate at the third level of spark gap set voltage= 2.6274 μm
= Average value of cutting rate at the third level of wire tension= 2.254074 μm

Substituting the values of various terms in the above equation,

= 1.799259 +2.296296 + 2.1922229 + 2.6274 + 2.254074 - 4(2.41) =1.526352 μm

The 95 % confidence intervals of confirmation experiments ( ) and population ( ) are calculated by using
the following Equations using the following Equations .

and

Where, Fα (1, ) = The F ratio at the confidence level of (1-α) against DOF 1 and error degree of freedom fe

neff =N/1+(DOF associated in the estimation of mean response)


n= =9
N= Total number of results= 27x3=81
R= Sample size of confirmation experiments=3
Ve = Error variance =0.03470 ___________________________________ From table(4)
fe = error DOF = 18
F 0.05 (1, 18) =4.494 _______________________________________ Tabulated F-value, Roy 1990 So,
= ±0.270477 and,
=±0.145524
Therefore, the predicted confidence interval for confirmation experiments is:
Mean - < < Mean +
1.255875 < < 1.796829
D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576 1575

The 95% confidence interval of the population is:


Mean – < < Mean +
1.110351< <1.401399

The optimal values of process variables at their selected levels are as follows:

1st level of pulse on time (A1) : 108 μsec


3rd level of pulse off time (B3) : 47 μsec
3rd level of peak current (C3) : 15 Amperes
3rd level of spark voltage (D3) : 68 volts
3rd level of wire tension (E3) : 8 grams

5.5 Confirmation experiment


In order to validate the results obtained, three confirmation experiments were conducted for the response
characteristics (surface roughness) at optimal levels of the process variables. The average values of the
characteristics were obtained and compared with the predicted values. The results are given in Table 7. The values
of Cutting Rate obtained through confirmation experiments are within the 95% of CI CE of respective response
characteristic. It is to be pointed out that these optimal values are within the specified range of process variables.
Table 7. Predicted Optimal Values, Confidence Intervals and Results of Confirmation Experiments

Performance Optimal Predicted Predicted Confidence Actual Value


Measures/ Set of Optimal Intervals at 95% (Average of Three
Responses Parameters Value Confidence Level Confirmation Experiments)
Surface CICE=1.255875 < < 1.796829
Roughness A1,B3,C3,D3,E3 1.526352μm CIPOP=1.110351< <1.401399 1.616352 μm

6. Conclusions
The effects of machining parameters on surface roughness with wire electric discharge machining (WEDM) process
has been studied with the aim of minimization of surface roughness utilizing Taguchi’s design. An optimal set of
machining process variables that yields the optimum quality features to machined components engendered by
WEDM process has additionally been obtained. The consequential conclusions from the present research work are
summarized in this chapter.

1. Ranges of Wire EDM process parameters have been established predicated on review of literature and by
performing the trail run experiments utilizing one factor at a time approach as in table8.
Table:8
UNITS
SNO PROCESS PARAMETERS SYMBOL RANGE
1 Pulse On Time ON 108-128 μsec
2 Pulse Off Time OFF 47-63 μsec
3 Peak Current IP 11-13 Amperes
4 Spark gap set Voltage SV 18-68 Volts
5 Wire Tension WT 2-8 Grams
6 Water Pressure WP 8-14 Kg/cm2

2. The effects of the process parameters viz. pulse on time, pulse off time, peak current, spark gap set voltage,
wire tension and water pressure on replication characteristics cutting rate. The optimal sets of process
parameters were obtained for sundry performance measures utilizing Taguchi’s design of experiment
methodology. The summary results of soothsaid optimal values of the replications and their confidence
intervals (both for attestation experiment and population) are given as under.
1576 D. Sudhakara and G. Prasanthi / Procedia Engineering 97 (2014) 1565 – 1576

REFERENCES:

[1]Speeding, T. A., Wang, Z.Q. (1997), “Parametric optimization and surface characterization of wire
electrical discharge machining process”, Precision Engineering, 20(1), 5-15.
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surface roughness in the WEDM process”, International Journal of Machine Tools & Manufacture,
40,1831–1848.
[3]Tosun, N. (2003)," The effect of cutting parameters on the performance of WEDM",KSME
international journal ,vol.17, No.6, pp.m816-824,2003
[4]Sarkar, S., Mitra, S., Bhattacharyya, B. (2005), “Parametric analysis and optimization of wire electrical
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[5]Hewidy, M.S., El-Taweel, T.A, El-Safty.M.F. (2005), “Modeling the machining parameters of wire
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[6]Mahapatra, S. and Patnaik, A. (2006), “Optimization of wire electrical discharge machining (WEDM)
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[7]Ross, P.J. (1996), “Taguchi techniques for Quality Engineering”, McGraw-Hill Book Company, New
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[8]Roy, R.K. (1990), “A primer on Taguchi method”, Van Nostrand Reinhold, New York.
[9]Kumar, P. (1993), “Optimization of process variables affecting the quality of Al-11%Si alloy castings
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machining", Ph.D. Thesis, National Institute Of Technology, Kurukshetra
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