Parametric optimization of wire electrical discharge machining (WEDM) process using taguchi method

Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts of hard materials with complex shapes. Parts having sharp edges that pose difficulties to be machined by the main stream machining processes can be easily machined by WEDM process. Technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted non-contact technique of material removal with a difference that spark is generated at wire and work piece gap. Since the introduction of the process, WEDM has evolved as a simple means of making tools and dies to the best alternative of producing micro-scale parts with the highest degree of dimensional accuracy and surface finish. This paper outlines the development of a model and its application to optimize WEDM machining parameters. Experiments are conducted to test the model and satisfactory results are obtained. The methodology described here is expected to be highly beneficial to manufacturing industries, and also other areas such as aerospace, automobile and tool making industries.