Parametric Optimization of Machining Parameters by using Annealed Copper Wire Electrode on Wire Electric Discharge Machining

In this work Annealed Copper wire is used to find performance of Wire Electrical Discharge Machining (WEDM) on D2 Steel with input variables like T ON time, Input Current, T OFF time, spark gap set voltage, wire runoff time and Tension of the wire. The experiments are conducted as per the standard Taguchi's L27 orthogonal array. The multiple performances like metal removal rate (MRR), Tool wear ratio (TWR), Surface roughness and kerf width (KW) are optimized by employing a Multi criteria decision making method called Technique for order preference by similarity to ideal solution (TOPSIS). By the results, the optimal arrangement of input variables are T ON-time 120 µs, T OFF- time 30 µs, Spark gap set Voltage 20 volts, Input Current 210 amps, Wire Tension 10 Kg-f and Wire runoff 2 m/min. Later, Analysis of variance is implemented and it shows that the T ON-time is the most important parameter that affects the output performances.