Optimization of Kerf Width, MRR and Surface Roughness of H-11 Material Machined with Wire Cut EDM Process Using Grey Relation Analysis

Abstract

In this study, the effects of cutting parameters on kerf width, MRR and surface roughness were experimentally investigated in WEDM. H-11 hot die tool steel was selected as the work material to conduct experiments. The factors selected for the optimization are the pulse on time, pulse off time, flushing pressure, wire tension, servo voltage and wire feed rate each of the factors in three different levels. An optimal parameter combination of the WEDM process was obtained by applying the grey relational analysis (GRA). Also, the analysis of variance (ANOVA) was carried out for finding out the contribution and the effects of machining parameters on the multiple performance characteristics (MPC). A Taguchi design of experiment (DOE) approach with L27 Orthogonal Array employed to conduct this experiment. Design Expert 8.0.6.1 software was used to perform the ANOVA (analysis of Variance) and confirmation test conducted to verify as well as compare the results from the theoretical prediction using software. And this research work develops new software tools in Visual basic-6.0. a. Develop scalar measurement software tool for measurement of kerf width b. ANOVA Analyzer software tool for analysis of variance.