Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
Study of the Performance of Wire EDM on Titanium
alloy using Taguchi Method
Anantalal Das1, Manoj Kundu2*
1
M.Tech student, ME Department, Dr. B.C. Roy Engineering College, Durgapur, India.
2*
Assistant Professor, ME Department, Dr. B.C. Roy Engineering College, Durgapur, India.
Email: [email protected]
Corresponding Email: 2*[email protected]
Received: 18 October 2022 Accepted: 06 January 2023 Published: 08 February 2023
Abstract: In this work, an experiment using wire electro-discharge machining to analyse
titanium alloy is described (WEDM). The goal is to examine how various process factors
affect a number of process performance indicators, including pulse width, servo reference
voltage, pulse current, and wire tension (such as cutting speed, wire rupture and surface
integrity).The Taguchi approach was used. Charmilles WEDM has been used in every
trial. It was also shown that both peak current and pulse interval can speed up cutting. It
has been demonstrated that surface roughness rises with pulse width and falls with pulse
interval.
Keywords: Wedm, Pulse on Time, Pulse off Time, Pulse Current, Taguchi Method.
1. INTRODUCTION
One of the most popular non-conventional material removal techniques is wire electrical
discharge machining. Researchers have successfully milled super alloys, composite materials,
high-speed steel (HSS), conductive ceramics, etc. using the WEDM technique. It has a
competitive advantage in the production of mould, die, and automotive, aircraft, and surgical
components because to its unique ability to use heat energy to treat electrically conductive
materials regardless of hardness. Using electrically conducting materials as the work piece
electrode and the tool electrode, both of which are enclosed in a dielectric fluid and separated
by a tiny gap, WEDM is a technique for eroding and removing material.Erosion is mostly
produced by local thermal activity brought on by an electric discharge. The material is
removed from the work piece by ionisation that occurs inside the discharge column between
the electrode and the work piece. This ionisation results in a localised high temperature and
extremely high energy density. The EDM process eliminates material as a result of thermal
erosion caused by melting and vaporisation. Figure 1 depicts the wire EDM technique
approximately. Wire-EDM is currently widely employed in the aerospace and automotive
Copyright The Author(s) 2023.This is an Open Access Article distributed under the CC BY
license. (http://creativecommons.org/licenses/by/4.0/) 33
Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
sectors after developing into a well-known non-traditional machining technique in recent
years. a tiny space and separated by a dielectric fluid.Even with the most sophisticated CNC
wire-EDM machines, selecting the cutting settings to enable better cutting efficiency or
precision has not yet been fully addressed. The intricate wire-EDM stochastic process
mechanisms are mostly to blame for this. The correlations between the cutting parameters
and cutting performance are therefore difficult to pinpoint with accuracy. The Material
Removal Rate (MRR), which is calculated as the rate at which material is removed from
surfaces, is one of the most significant performance indicators (results) of the WEDM
process. Wire feed, wire tension, spark gap voltage, servo feed, corner servo voltage, flushing
pressure, pulse-on-time, and pulse-off time are some of these factors. The only approach to
enhance the performance of the WEDM process is to set the optimal values for certain
process parameters.
Experiment Details
Optimization Techniques
Taguchi suggested a sturdy design that was based on an experimental design. The best tool
for performance characteristic parameter design is provided by this technique. The design of
the experiment entails choosing the proper orthogonal array and assigning the components
and interactions to the proper column. By adopting an orthogonal array, the Taguchi
technique lowers the number of tests, which eases the burden of extensive testing. By
reducing variability around the target value, Taguchi's resilient design technique aims to
attain a goal value. Taguchi employs the SN ratio as a performance indicator when a
characteristic deviates from its intended value and simulates quality degradation using a
quadratic function. The key difference between SN ratio and other techniques is that it
analyses mean and variance as separate performance metrics, whereas other approaches
consider a response variable's location and dispersion as a single performance parameter.The
response variables were often divided into three categories by Taguchi (Phadke, 1989):
smaller-the-better (STB), larger-the-better (LTB), and nominal-the-best (NTB). The
following are the formulas for determining the SN ratio (ij) for the jth response corresponding
to the ith trial (i = 1, 2... m; j = 1, 2... p), which vary depending on the kind of response
variable used:The HTB response variable is
1
S/N Ratio = 10 log10 (1/ n)∑𝑛𝑖=1 2 (1)
𝑦𝑖𝑗
For STB response variable
S/N Ratio = 10 log10 (1/ n )∑𝑛𝑖=1 2
𝑦𝑖𝑗 (2)
In order to determine the percentage contribution of each parameter to the output parameter
against a given degree of confidence, the Analysis of Variance (ANOVA) is used to the
results of experiments. This study investigated the effects of eight input factors, such as the
timing of the pulse on and off, the corner servo voltage, the flushing pressure of the
dielectricfluid, the wire feed, the wire tension, the spark gap voltage, and the servo feed,
using an L20 orthogonal array.
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Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
Work Material
Titanium alloy (Grade 12)
Chemical composition :- Ti – Balance , C – 0.08 , N – 0.03 , Ni – 0.06 to 0.09 , Fe – 0.30 , O
– 0.25 , O – 0.25 , H – 0.015 , Mo – 0.2 to 0.4
Mechanical properties: - Hardness61HRB, Yield Strength 345 Mpa , Density 4.51g/cm3
Experimental Procedure
On a CNC WEDM machine called the Ultra Cut 843/ULTRA CUT f2, the studies were
conducted. All of the axes on this machine may be configured to operate in accordance with
CNC code that is input through the control panel and are servo driven. Each of the three axes
has 1 m accuracy. The electrode was made of brass wire that had a 0.25 mm diameter. The
distance between the wire and work piece is extremely small—between 0.025 mm and 0.05
mm. The high energy density erodes material from the wire and the work piece by producing
localised melting and vaporisation. To eliminate the debris created during the erosion, the
dielectric fluid (deionized water) is constantly flashed through the gap along the wire and into
the sparking region.The used wire erosions are collected in a tank at the bottom and then
thrown away. Because of the variance in dimensional precision, the wires cannot be used
again. Machining may be programmed using an NC code. In the current body of study, wire-
cut electrical discharge machining of titanium alloy has been taken into account. A work
piece with dimensions of 10 mm in width, 10 mm in length, and 15 mm in cut depth is used
in the wire-cut EDM experiment. The experiment makes use of an L36 (21 X 37) mixed
orthogonal array constructed utilising the Taguchi approach and resilient design.The three
objectives while establishing machining parameters are to maximise MRR, minimise SR, and
minimise gap width, especially in rough cutting operations. Typically, the manufacturer of
the machine tool supplies a table of machining parameters that may be used to establish
machining parameters. The operators' expertise is crucial to this operation. Due to the
abundance of configurable machining factors, it is quite challenging to use a machine's best
features in practise. A straightforward yet dependable technique based on statistically planned
trials is used to analyse the effects of various process parameters on MRR, SR, and Gap
width and to identify the best process settings.Data were gathered for the current study from a
few experimental runs using factor combinations that were chosen at random. To pinpoint the
process and create a rough relationship between the various process parameters and the
response variables, a quadratic model has been fitted. These mathematical models were used
to provide data in accordance with Taguchi design. The best process environment has been
determined using the grey-based Taguchi approach. For optimality analysis during the
machining of titanium alloy, three levels for the remaining seven control variables and two
levels for one of the eight WEDM parameters (Pulse on time) are taken into consideration.
Experimental variables and their magnitudes for the process of WEDM
Parameter Symbol Level 1 Level 2
Corner servo CS (volts) 60 70
Pulse On Time T ON (µs) 110 116
Pulse Off Time T OFF (µs) 55 60
Wire feed rate € WF (m/min) 3 6
Wire tension WT (Kg-f) 8 9
Copyright The Author(s) 2023.This is an Open Access Article distributed under the CC BY
license. (http://creativecommons.org/licenses/by/4.0/) 35
Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
Flushing pressure WP (Kg/cm2 ) 7 9
Servo Feed SF (mm/min) 1000 1200
Spark Gap Voltage SV (volts) 18 23
2. EXPERIMENTAL RESULTS
Exp. No. T ON T OFF CS WP WF WT SV SF MRR
1 1 2 2 2 1 1 1 1 119.2
2 1 2 2 2 2 3 3 3 133.1
3 1 3 3 3 3 2 2 3 174.1
4 1 2 2 3 1 2 2 2 118.2
5 1 2 2 2 2 3 3 3 129.5
6 1 1 2 3 3 1 1 1 182.5
7 1 1 1 2 3 1 2 3 109.3
8 1 1 3 3 1 2 3 1 139.3
9 1 3 3 3 3 1 1 2 189.5
10 2 2 1 3 2 1 3 2 110.3
11 1 2 2 1 3 3 2 3 150.8
12 1 2 3 2 1 3 2 1 200.2
13 1 1 2 3 1 3 2 1 112.6
14 1 2 3 1 3 1 2 2 119.1
15 1 3 1 2 3 2 1 3 139.1
16 1 1 2 3 2 1 1 3 125.7
17 1 2 3 1 2 3 2 1 129.8
18 1 3 1 2 1 3 3 2 188.5
19 2 1 2 3 2 3 3 1 368.1
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license. (http://creativecommons.org/licenses/by/4.0/) 36
Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
20 2 2 3 2 1 1 1 2 321.5
Using the statistical programme MINITAB 16, the experimental data generated by the
Taguchi experimental design were statistically analysed. To ascertain how the input
parameters impacted the output response variables, analysis of variance (ANOVA) was
utilised.
Response values are calculated as the mean effect plot of material removal rate as corner
servo voltage, dielectric fluid flushing pressure, wire feed, wire tension, spark gap voltage,
and servo feed on MRR under the selected machining settings. Calculated response values are
summarised in a table and displayed in a figure. Figure 2 for the raw data shows the typical
material removal rates for each parameter at levels 1, 2, and 3. It shows that as the pulse on
time grows, so does the rate of material removal.The corner servo voltage and time pulse
hardly affect how quickly material is removed. There is a transient rise in pulse off time and
corner servo voltage, which occurs after a little increase in MRR.
Parameter Level1 Level 2
T ON 136.213 309.921
T OFF 226.566 215.632
CS 219.011 212.189
WP 223.401 223.552
WF 217.360 219.602
WT 215.762 212.654
SV 205.168 230.112
SF 222.272 211.557
Combination of optimal process parameters using Taguchi method
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Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
Response
Optimal Parameter Combination characteristics
values
Response
S. No. characteristics Experimental
TON TOFF CS WP WF WT SV SF OA value
MRR
1 (mm3/min) 2 3 3 2 3 3 3 1 326.5 355.5
Experiment results
process parameters (Optimal)
Response parameters Experimental value
Assumed value
MRR (mm3/ min) 123.375 139.5
3. CONCLUSION
This work used the Taguchi technique, traditional utility analysis, and principal component
analysis for weighting to offer the multi-objective optimization process parameters for
WEDM of Titanium alloy. The statistical analysis (ANOVA) showed that the main
machining parameter considered in this study enhances the WEDM method machining's
performance. ANOVA was used to statistically validate the mathematical model that was
provided for forecasting the ideal conditions of material removal rate, Spark Gap, and surface
roughness.The findings of the ANOVA test demonstrate that the two machining parameters
pulse on time (T ON) and wire tension have a significant impact on the rate of material
removal during the WEDM process (WT). The wire feed, Spark Gap, and pulse on time all
have a significant impact on surface roughness. Corner servo voltage (CS), wire feed rate
(WF), and wire tension are the three machining variables that have the greatest impacts on
spark gap (WT).
Future Scope
Even though WEDM machining for Titanium alloy Grade 12 has been fully studied, there is
still need for more research. The following recommendations can be beneficial for upcoming
work.
● It is important to look at how different machining parameters affect the overcut and
recast layer thickness.
● In the WEDM process, electrodes made of brass or graphite may be utilised in place
of copper electrodes.
● Only four machining parameters are selected for this investigation. A detailed study
can be done, considering other parameters also.
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license. (http://creativecommons.org/licenses/by/4.0/) 38
Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
Acknowledgement
I pay my deep sense of gratitude to Asst. Prof. (Dr.) Manoj Kundu for encouraging me
immensely and providing me the opportunity to prepare this report. I also highly obliged to
my all associate faculty member for their elevating inspiration, encouraging guidance and
kind supervision in the completion of the report.
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Journal of Electronics, Computer Networking and Applied Mathematics
ISSN: 2799-1156
Vol: 03, No. 02, Feb-Mar 2023
http://journal.hmjournals.com/index.php/JECNAM
DOI: https://doi.org/10.55529/jecnam.32.33.40
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