Multi Objective Optimization of Wire EDM Angular Cutting on AISI D2 Steel Using Desirability Function

Due to its distinctive features AISI D2 tool steel is used in various industries and the characteristics of this alloy make difficult for machining it by traditional method. Machining harder materials is a difficult task which is accomplished efficiently by electrical discharge machining (EDM) process. The present work is focussed on investigation of angular cutting in EDM using response surface methodology (RSM). Experiments are performedtofind the impact of input factors taper angle, wire feed and wire tension on the response parameters cuttingspeed, angular error and surface roughnessby using statistical design of experiments. Desirability approach is applied for multi objective optimization for targeting maximum cutting speed and minimum angular error and surface roughness. Results show thatthe taper angle was the most influencing parameter and the parameters optimization levels of operating are taper angle 6.31°, wire feed 4.33 mm/min and wire tension 7.29 g respectively. Desirability of 0.902 was achieved with response values as cutting speed 0.001mm/min, angular error 2.473°and surface roughness 1.063 μm.Confirmation tests are carried and found to be in good contract with investigational results