Modeling and Optimization of WEDM Process Parameters on Machining of AISI D2 steel using Response Surface Methodology (RSM)

Abstract

The present work demonstrates optimization of Wire Electrical Discharge Machining (WEDM)
process parameters of AISI D2 steel with multiple performance characteristics such as Cutting Rate and Gap
Current on the Response Surface Methodology (RSM) Method. The process parameters considered in this
research work are Pulse On-time, Pulse Off-time and Wire Feed. Taguchi’s L9 Orthogonal Array was used to
conduct experiments. Optimal levels of process parameters were identified using Response Surface
Methodology and the relatively significant parameters were determined by Analysis of Variance (ANOVA). The
variation of output responses with process parameters were mathematically modelled by using non-linear
regression analysis method and the models were checked for their adequacy. Result of confirmation experiments
shows that the established mathematical models can predict the output responses with reasonable accuracy.