Optimizing surface finish in WEDM using the taguchi parameter design method

Abstract

Wire electrical discharge machining (WEDM) is extensively used inmachining of materials when precision is of major factor. Selection of optimum machining parameter combinations for obtaining higher accuracy is a challenging task in WEDM due to the presence of a large number of process variables and complex stochastic process mechanisms. Inthe present work, WEDM of titanium alloy (Ti6Al4V) is experimentallystudied. The behavior of eight control parameters such as Ignition pulse current (A), Short pulse duration(B), Time between two pulses(C),Servo speed(D), Servo reference voltage(E), Injection pressure(F), Wire speed(G) and Wire tension(H) on surface finish was studied using Taguchi parameter design. A mathematical model is developed by means of linear regression analysis to establish relationship between control parameters and surface finish as process response. An attempt is made to optimize the surface roughness prediction model using Genetic Algorithm (GA). Optimum values of control parameters at level A1, B1,C1, D 3, E1, F3, G2, H3 for the selected range and workpiece material are obtained. copyright © 2010 by ABCM.