Comprehensive Analysis of Wire Electric Discharge Machining Process in Machining High Chromium High Carbon Steel

Every manufacturing industry primarily concentrates on yielding maximum profit with minimal expenditure where profit directly depends on the production cost and quality of the product. The firm aims at maximum production rate with minimum production cost and maximum surface quality. The minimal production cost and surface finish can be achieved by proper selection of combination of machining parameters, interaction study between of machining parameters and identification of the most contributing parameter for a specific response. Modern manufacturing industries have adopted different advanced machining processes for machining hard and difficult to machine materials. Wire Electric Discharge Machining process is the most adopted when considering machining of rectangle contour profile. The work mainly reflects on performance analysis of machining parameters in producing different contour shapes using Wire Electric Discharge Machining parameters. The consequence of the Machining parameters such as Pulse ON time, Pulse OFF time and MAO over the Machining time and Surface Roughness has been analyzed. The interaction study is made by Response Surface methodology. Analysis of Variance is used to identify the most significant parameters for the respective responses. The MAO had greater impact on Surface Roughness followed by Pulse ON time. The Pulse ON time was encountered as the most contributing parameter, for Machining Time. The average deviation between the empirical and predicted model for surface roughness was recorded as 0.03%, whereas 0.023% deviation was observed for Machining time. The regression model was developed for both Surface roughness and Machining time. Validation of models proved that, the developed models can be used to predict the responses.