Multi-Objective Optimization of WEDM Process Applying Statistical Methodology

The present study aims at determining parametric influence and optimum process parameters of wire electrical discharge machining (WEDM) during machining mild steel by copper wire using Taguchi's technique. Experiments are designed as per Taguchi's L27 orthogonal array. The level of importance of the machining parameters on the responses is determined by using analysis of variance. Mathematical model for all three important performance measures such as high material removal rate, lower surface roughness and low overcut are developed and the responses are used for studying the inter-relationship between performance measures and process parameters viz. pulse on time, pulse off time, wire tension, and wire feed rate. An experimental plan for Box-Behenken Design has been conducted according to response surface methodology and subsequently to seek the optimal parameters. The optimal settings of operating conditions are predicted using desirability function. This paper presents a formulation and solution of a multiobjective optimization problem for the selection of the best control settings on a WEDM.