Multi objective optimization for kerf and material removal rate in wire electrical discharge machining using Taguchi method combined grey relational analysis

Abstract

This paper investigated the multi performance characteristics of wire electrical discharge machining for an optimal machining parameters to get low kerf and high material removal rate at the same time. The machining parameters i.e arc on time, on time, servo voltage and wire feed were used in this experiment. Based on L9 orthogonal array, the signal-to-noise (S/N) ratio and the analysis of variance (ANOVA) was used to study the machining parameters of DIN 1.2510 tool steel. Multi response characteristics were solved by Taguchi method combined grey relational analysis. Experimental results are provided to demonstrate the effectiveness of this method i.e. kerf decreased from 354 μm to 345 μm, while material removal rate (MRR) increased from 9,313 mm3/min to 13,989 mm3/min. From the optimization result validated in the confirmation experiment the machining parameters combination that could produce the optimum responses are arc on time of 2 A, pulse on time of 8 μs, servo voltage 80 V and wire feed 60 mm/min.