Optimisation of Wire-EDM Process Parameters for Achieving Low Surface Roughness in Machining of Is 5986 Fe 410 Steel and Regression Modelling

Non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters namely current (Ic ), pulse-on time(Ton), pulse-off time (Toff), wirespeed (Ws ) and voltage (Iv ) on surface roughness (SR) is investigated while machining non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters namely current (Ic ), pulse-on time(Ton), pulse-off time (Toff), wire-speed (Ws ) and voltage (Iv ) on surface roughness (SR) is investigated while machining of IS 5986 FE 410 steel by wire-electrical discharge machine (wire- EDM). The experiments were designed using Taguchi L16 arrays and results are analyzed using statistical methods. The process parameters such as Ic, Toff and Ws showed a significant contribution by 66.22 %, 13.77 % and 9.25 % respectively on SR. Further, the process parameters were optimized to obtain a minimum SR which produced in Ra values 1.480 µm at settings Ic -4 A, Ton- 40 µs, Ton - 10 µs, Ws - 1400 rpm and Iv - 80 V. Regression model is developed to predict the SR at different settings for the control parameters which predicted the response with average predication an error of 11.08 %