Optimization of Wire Electric Discharge Machining (WEDM) process parameters for AISI 1045 Medium Carbon Steel using Taguchi Design of Experiment

The demand for alloy materials with high hardness, toughness, and impact strength has increased with the growth of the manufacturing industry. These materials are extremely difficult to manufacture using standard techniques, hence, non-conventional machining is used to solve this problem. Wire cut electric discharge machine is one of them. Thus, to attain the required outcome or productivity, it is necessary to control the input parameters that affect the response factors. This research aims to optimize the wire cut electric discharge machining process parameters using the Taguchi design of experiment (DOE) for AISI 1045 medium carbon steel. In this work, experiments are performed in an automotive sector to analyze the influence of WEDM process parameters such as current, voltage, and pulse on time on material removal rate (MRR) for AISI 1045 medium carbon steel. The signal-to-noise (S/N) ratio and analysis of variance are used to analyze the impact of error in this experiment, establishing the best set of process parameters for optimizing the material removal rate. According to the present investigation, the current has a significant effect on the material removal rate. The observed optimal process parameter settings for higher material removal rate based on the Taguchi DOE were found to be, I=16amp,V=60volt, pulse on time =100µs .The conclusion of the paper includes the disclosure of findings, analysis, and judgments.