Modeling and Optimization of WEDM Process Parameters on Machining of AISI D2 using Taguchi Method

Since it is frequently used for die-punch development and the machining of hard, brittle materials, wire electric discharge machining, or WEDM, is a commonly used machining method in various industries. When producing complicated shapes, WEDM is also utilized. The choice of the right machining factors has a significant impact on how well the WEDM machining process performs. One method utilized in the manufacturing sector to find the ideal circumstances for production is optimization, which is crucial for firms hoping to produce high-quality goods at lower costs. The WEDM machining process involves a large number of process variables, making it challenging to select the right mix of these variables to optimize material removal rate while reducing tool wear and surface roughness. The aim of this study is to examine the impact of process variables, including wire feed, servo voltage, peak current, pulse on and off times, and Surface roughness, gap voltage, gap current, and cutting rate, on performance metrics in the WEDM machining process. The WEDM process’s impacts on process parameters are estimated, and a set of ideal parameters for the process’s best performance is predicted, using the Taguchi technique. To determine the degree of importance of each process parameter in each case, ANOVA has been used. This technique has the potential to greatly improve process performance, as demonstrated by experimental verification of the obtained results