Investigating wire electric-discharge machining (WEDM) parameters for improved machining of D2 steel: a multi-objective optimization study

Official URL: https://dx.doi.org/10.1007/s12541-024-01203-4

Wire Electric-Discharge Machining (WEDM) represents a non-traditional approach to metal cutting, providing the advantage of precision manufacturing over conventional methods. In recent years, the metal machining industry has witnessed numerous benefits in terms of high speed and accuracy through the utilization of WEDM in both additive and subtractive manufacturing processes. This research focuses on studying the process parameters and their impact on surface roughness, energy consumption, kerf width, and material removal rates in Wire Electric-Discharge Machining of D2 steel. The Taguchi approach to experimental design (L16) was employed to conduct cutting experiments at varying levels of ON Time, OFF Time, Servo Voltage, and Wire Tension. Experimental results were optimized using ANOVA and Grey Relational Analysis to refine the process inputs and achieve performance measures that minimize surface roughness, power consumption, and kerf width while maximizing material removal rate. Statistical analysis revealed that ON Time is the most significant factor (73%) affecting both individual and multiple responses. The optimized model indicates that significant improvements can be simultaneously achieved in all response parameters by selecting the optimal combination of parameters. This not only enhances the part quality but contributes positively towards process sustainability and productivity.