Optimization of Process Parameters of WEDM Process for Machining D2 Tool Steel

This paper presents an investigation of WEDM process using molybdenum wire as electrode on D2 tool steel. WEDM is a thermal machining process that utilizes spark discharges to erode a conductive material. Optimum machining conditions were obtained with maximum cutting rate and minimum surface roughness as objective. It was observed that with increase in peak current, cutting speed and surface roughness increases. Response surface methodologies D optimality test was used to determine the optimal machining parameters, among which the peak current for cutting speed and the gap voltage for surface roughness were found to be the most significant. The obtained optimal machining conditions are peak current of 16 A, voltage of 190 V, Pulse on time of 115 µs, Pulse off time of 40 µs and Wire tension of 6 N which is validated by confirmation test.