Investigation of the Effect of Process Parameters on Material Removal Rate in Machining of IS 5986 Fe 410 Steel by Wire-EDM: The Optimization and Regression Modeling

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 material removal rate (MRR) 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 analysed using statistical methods. The process parameters such as Toff, Ic and Ws showed significantly the contribution by 54.17%, 22.08% and 13.77%, respectively, on MRR. Further, the process parameters were optimized obtaining higher MRR which yielded 1.23 mg/s at settings Ic -5A, toff-40 µs, Toff-5 µs, Ws - 1400 rpm and Iv - 90 V. Regression model is developed to predict the MRR with the control parameters with
2 values 89.30%. The model predicting accuracy of the model is verified by the confirmation experiments.