Assistant Professor, Department of Automobile Engineering, Nehru Institute of Technology, Coimbatore
Wire Electrical discharge Machining plays an important role in the field of strong conductive metal machining. It offers accuracy, precision, ability to achieve intricate profiles, complex shaped components of any hardness, unmanned machining, less noise and residual stress on work. WEDM is stochastic process and hence difficult to determine parameters for the improvement of cutting performance and optimization. The material and the machining hours are expensive, hence instead of rule of thumb or manufacturer's catalogue, DOE using Taguchi‟s robust design L16 orthogonal array with four important parameter at four levels each was applied on O2 Tool steel. The optimum machining parameter combination was obtained by using the signal-to-noise ratio and the level of importance of the machining parameters on the material removal rate and surface roughness were determined from analysis of variance. Confirmation experiment was carried out. The results indicates high spark duration, low wire-electrode speed and gap voltage characteristics improves material removal by 29.5%,whereas, lower pulse duration, gap voltage and high wire-electrode speed, reduces the surface roughness by 11%. This result could be used for multi-pass rough cuts or fine finish cut.