PARAMETRIC ANALYSIS AND OPTIMIZATION OF POWER CONSUMPTION IN CNC-WIRE EDM USING GENETIC ALGORITHM

The purpose of this paper is to optimize process variables of CNC-WEDM to obtain maximum MRR and minimum Power consumption in rough cutting. This paper explains Wire electrical discharge machining (WEDM) and design of experiment. The material used in this project is D3. Standard Roughing Intensity power and others factor (pulse on time, pulse off time and servo speed) have been studied. The material was cut using brass wire of diameter 0.25mm using dielectric media for various operating conditions. The design of experiment (DOE) method was utilized to find the best combination of the parameters setting to achieve the maximum Material Removal Rate (MRR) and minimum Power consumption to study the interaction between factors that can affect the response. With the result of analysis using DOE the confirmation process on the material have been done. The mathematical models are developed using regression analysis. The GA is used as optimization process to study the optimum settings for minimum power consumed and maximum MRR. The optimum parameters on the material removal rate and Power consumed have been discussed. The most importance of this work is the information about the optimum selection of parameter setting in machining of alloy steel. This information is useful for industries to produce many kinds of components using alloy steel material by saving time and cost while maintaining the accuracy and efficiency machining by CNC-WEDM