Effects of Machining Parameters on Tool Steel D2 in Wire cut EDM

Abstract

Non-conventional machining process like electro discharge machining (EDM) and wire electrical discharge machining (WEDM) plays important role in precision manufacturing process. This micro-machining process may help overcome the limitations and restriction faced during conventional mechanical machining process.The selection of machining parameters in any machining process significantly affects production rate, product quality and production cost of a finished one component. Wire EDM process involves a large number of variables that affect its performance. In this paper, an attempt is made to study the effect of various process parameters such as pulse on time, pulse off time and current for high carbon high chromium cold work tool steel (D2). The experiment has been completed with the help of Design of experiment by Taguchi method is applied to create an orthogonal array of input variables using the ANOVA. The regression analysis is used to optimize the process parameter of Surface roughness. The experimental analysis showed that the combination of pulse on time, pulse off time and current is optimum to achieve minimization of surface roughness (Ra).