Optimization of Wire Electro Discharge Machining of HCHCr Material using Taguchi Methodology

Abstract: In this paper, the cutting of High Carbon High Chromium (HCHCr) material using Wire electro discharge machining (WEDM) with a brass wire by using Taguchi methodology has been reported. The Taguchi method is used to formulate the experimental layout, to analyze the effect of each parameter on the machining characteristics, and to predict the optimal choice for each WEDM parameter such as Pulse on time, Pulse off time, feed, Sensitivity. It is found that these parameters have a significant influence on machining characteristic such as material removal rate (MRR), Overcut (OC) and Surface Roughness (Ra). The analysis using Taguchi method reveals that, in general the feed and sensitivity significantly affects the MRR and Pulse on time and Pulse off time has the favorable effect on the Ra. Keywords: WEDM, Taguchi method, HCHCr, material removal rate, Overcut and Surface roughness.