Experimental Investigation of MRR and Surface Roughness of Stainless Steel 410s in Wire EDM Using Grey Taguchi Method

Wire electrical discharge machining (WEDM) has become an important non-traditional machining process which is used to manufacture complex contours with great accuracy and excellent surface finish. Wire EDM is a very complex process involving the different process parameters. In the present investigation and optimization of wire EDM has been carried out by using grey taguchi optimization process. The process parameters involved is pulse on time, pulse off time, wire feed rate, table feed rate and servo voltage. Surface roughness (SR) and Material removal rate (MRR) are taken as response factor. Experimental investigation carried out in ECOCUT wire EDM machine. Stainless steel 410 is subjected to machining by a tool of brass wire of 0.25mm diameter and deionized water is used as dielectric fluid. For this experiment, mixed level orthogonal array has been used. The main objective of the study is to find out the best combination of process parameters for high material removal rate and low surface roughness, by the help of analysis of variance (ANOVA) which is useful to identify the most important factor or input parameter that most affects the performance of machining. Finally Optimal setting has been verified through confirmation test and results good agreement to the predicted value