Optimization of Process Parameters of Wire Electrical Discharge Machining Using Fuzzy logic Integrated with Taguchi Method

In this paper, fuzzy logic integrated with the Taguchi method is used to optimize Wire Electro Discharge Machining (WEDM) process with multiple quality characteristics. Rough machining with EDM gives poor surface finish and has micro cracks and pores. Finish machining gives better surface finish but with very poor machining speed (MRR). Spark gap width is one of the important performance measures in WEDM. Spark gap width is the measure of the amount of the material that is wasted during machining. It determines the dimensional accuracy of the finishing part. In setting the machining parameters, the main goal is the maximum MRR with the minimum surface roughness and minimum spark gap width. Hence achieving higher MRR along with lower SR and SG can be considered as a multi-objective optimization problem.

This paper discusses the application of the Taguchi method with fuzzy logic to optimize the machining parameters for Wire electrical discharge machining of Inconel 825 with multiple characteristics. A multi-response performance index (MRPI) was used for optimization. The machining parameters viz., pulse on time, pulse off time, corner servo voltage, flushing pressure, wire feed, wire tension, spark gap voltage, servo feed were optimized with consideration of multiple performance characteristics. The results from confirmation runs indicated that the determined optimal combination of machining parameters improved the performance of the machining process.