Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method

Wire electrical discharge machining (WEDM) is extensively used in machining of conductive materials when precision is of prime importance. Rough cutting operation in WEDM is treated as a challenging one because improvement of more than one machining performance measures viz. metal removal rate (MRR), surface finish (SF) and cutting width (kerf) are sought to obtain a precision work. Using Taguchi's parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration, pulse frequency, wire speed, wire tension, and dielectric flow. It has been observed that a combination of factors for optimization of each performance measure is different. In this study, the relationship between control factors and responses like MRR, SF and kerf are established by means of nonlinear regression analysis, resulting in a valid mathematical model. Finally, genetic algorithm, a popular evolutionary approach, is employed to optimize the wire electrical discharge machining process with multiple objectives. The study demonstrates that the WEDM process parameters can be adjusted to achieve better metal removal rate, surface finish and cutting width simultaneously.