Optimization Of Process Parameters In Wire-Edm Using Response Surface Methodology
Wire electrical discharge machining has become an important non-traditional machining process, as it provides
an effective solution for producing components made of difficult-to-machine materials like tungsten carbide, titanium,
zirconium etc., and intricate shapes, which are not possible by conventional machining methods. This research paper deals
with Response Surface Methodology approach for maximizing the material removal rate in wire electrical discharge
machining. The investigated machining parameters were wire tension, pulse on time and peak current. Machining was
carried on AISI D2 cold work steel, which is widely used in die and mold making industries. The experiments were designed
based on response surface design method; in which central composite design method was applied for fitting the second order
model. After the experimentation, the effect of the parameters on MRR was determined by analysis of variance (ANOVA).
Also the interaction of their parameters was considered for their significance. Regression analysis was done and a second
order mathematical model was fitted for MRR considering the parameters and their significant interactions. And at last
optimization was carried using desirability approach and confirmation experiments were performed.