Skip to main content
SpringerLink
Log in

Multi-response optimization of WEDM parameters on machining 16MnCr5 alloy steel using Taguchi technique

  • Original Paper
  • Published:
Multiscale and Multidisciplinary Modeling, Experiments and Design Aims and scope Submit manuscript

Abstract

In this present work, an attempt has been made to optimize the wire electric discharge machining using muli-response optimization technique based on Taguchi’s design approach. 16MnCr5 Alloy steel was selected as workpiece material. The response parameters viz. material removal rate and surface roughness were optimized by varying types of electrode, pulse on time (Ton), pulse off time (Toff) and peak current (Ip). The Taguchi’s L18 mixed orthogonal array has been used for planning and designing the experiments. ANOVA was used to find the contribution and significance of different process parameters on the response parameters. The results clearly indicated that pulse on time (Ton) was the most influential factor for the material removal rate and surface roughness. Optimal level of process parameters was used to perform the confirmatory experiments which verified the improvements in performance characteristics.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

Abbreviations

V c :

Cutting Speed

M t :

Thickness of workpiece material (mm)

W d :

Diameter of the wire (mm)

T on :

Pulse on time

T off :

Pulse off time

I p :

Peak current

WEDM:

Wire electrical discharge machining

MRR:

Material removal rate

SR:

Surface roughness

ANOVA:

Analysis of variance

S/N:

Signal to noise ratio

References

  • Aggarwal V, Khangura SS, Garg RK (2015) Parametric modeling and optimization for wire electrical discharge machining of Inconel 718 using response surface methodology. Int J Adv Manuf Technol 79(1):31–47

    Article  Google Scholar 

  • Babu TV, Soni JS (2017) Optimization of process parameters for surface roughness of Inconel 625 in wire EDM by using Taguchi and ANOVA method. Int J Curr Eng Technol 7(3):1127–1131

    Google Scholar 

  • Benedict GF (1987) Electrical discharge machining (EDM). Non-traditional manufacturing processes. Marcel Dekker Inc, New York, Basel, pp 231–232

    Google Scholar 

  • Bobbili R, Madhu V, Gogia A (2015) Modelling and analysis of material removal rate and surface roughness in wire-cut EDM of armour materials. Eng Sci Technol Int J 18(4):664–668

    Article  Google Scholar 

  • Çetinkaya C, Arabaci UU (2006) Flash butt welding application on 16MnCr5 chain steel and investigations of mechanical properties. Mater Des 27(10):1187–1195

    Article  Google Scholar 

  • Han F, Jiang J, Yu D (2007) Influence of machining parameters on surface roughness in finish cut of WEDM. Int J Adv Manuf Technol 34(5):538–546

    Article  Google Scholar 

  • Ho K, Newman S, Rahimifard S, Allen R (2004) State of the art in wire electrical discharge machining (WEDM). Int J Mach Tools Manuf 44(12):1247–1259

    Article  Google Scholar 

  • Huang J, Liao Y (2003) Optimization of machining parameters of wire-EDM based on grey relational and statistical analyses. Int J Prod Res 41(8):1707–1720

    Article  MATH  Google Scholar 

  • Kanlayasiri K, Boonmung S (2007a) Effects of wire-EDM machining variables on surface roughness of newly developed DC 53 die steel: design of experiments and regression model. J Mater Process Technol 192:459–464

    Article  Google Scholar 

  • Kanlayasiri K, Boonmung S (2007b) An investigation on effects of wire-EDM machining parameters on surface roughness of newly developed DC53 die steel. J Mater Process Technol 187:26–29

    Article  Google Scholar 

  • Kapoor J, Singh S, Khamba JS (2011) Current research trends on wire electrodes for wire electrical discharge machining. Int J Eng Sci 1(1):168–175

    Google Scholar 

  • Khatri BC, Rathod PP (2017) Investigations on the performance of concentric flow dry wire electric discharge machining (WEDM) for thin sheets of titanium alloy. Int J Adv Manuf Technol 92:1945–1954

    Article  Google Scholar 

  • Kumar V, Jangra K, Kumar V (2012) Effect of WEDM parameters on machinability of Nimonic-90. In: Proceedings of the national conference on trends and advances in mechanical engineering (TAME), YMCA University of Science and Technology

  • Kumar R, Kohli A, Singh S, Ashri D (2014) Effect of various wire electrodes’ material on cutting rate of D3 material. Int J Res Technol Stud 1(5):22–25

    Google Scholar 

  • Kumar A, Mishra H, Vivekananda K, Maity K (2017a) Multi-objective optimization of wire electrical discharge machining process parameterson Inconel 718. Mater Today Proc 4(2):2137–2146

    Article  Google Scholar 

  • Kumar K, Kumar P, Jain SK, Kumar S (2017b) Experimental investigation and multi objective optimization for wire EDM using Taguchi’s method. Int Res J Eng Technol 4(6):1318–1320

    Google Scholar 

  • Liao Y, Woo J (1997) The effects of machining settings on the behavior of pulse trains in the WEDM process. J Mater Process Technol 71(3):433–439

    Article  Google Scholar 

  • Mahapatra S, Patnaik A (2007) Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method. Int J Adv Manuf Technol 34(9):911–925

    Article  Google Scholar 

  • Malik A, Rohilla V, Gehlot N (2015) Optimization of machining parameters for WEDM of medium carbon steel C45 Using Taguchi-based grey relational analysis. IUP J Mech Eng VIII(4):15–26

    Google Scholar 

  • Manjaiah M, Laubscher RF, Kumar A, Basavarajappa S (2016) Parametric optimization of MRR and surface roughness in wire electro discharge machining (WEDM) of D2 steel using Taguchi-based utility approach. Int J Mech Mater Eng 11(1):7

    Article  Google Scholar 

  • Mishra SK, Singh S, Singh S, Singh S, Mandal A, Kumar S, Garg R (2016) Optimization of process parameters in WEDM process. Int J 4(1):69–73

    Google Scholar 

  • Pasam VK, Battula SB, Madar Valli P, Swapna M (2010) Optimizing surface finish in WEDM using the Taguchi parameter design method. J Braz Soc Mech Sci Eng 32(2):107–113

    Article  Google Scholar 

  • Pramanick A, Sarkar S, Dey PP, Das PK (2016) Optimization of wire electrical discharge machining parameters for cutting electrically conductive boron carbide. Ceram Int 42(14):15671–15678

    Article  Google Scholar 

  • Raju P, Sarcar M, Satyanarayana B (2014) Optimization of wire electric discharge machining parameters for surface roughness on 316 L stainless steel using full factorial experimental design. Proc Mater Sci 5:1670–1676

    Article  Google Scholar 

  • Rao TB (2016) Optimizing machining parameters of wire-EDM process to cut Al7075/SiCp composites using an integrated statistical approach. Adv Manuf 4(3):202–216

    Article  Google Scholar 

  • Reddy CB, Reddy VD, Reddy CE (2012) Experimental investigations on MRR and surface roughness of EN 19 & SS 420 steels in wire EDM using Taguchi method. Int J Eng Sci Technol 4(11):4603–4614

    Google Scholar 

  • Shah C, Mevada J, Khatri B (2013) Optimization of process parameter of wire electrical discharge machine by response surface methodology on Inconel-600. Int J Emer Technol Adv Eng 3(4):2250–2459

    Google Scholar 

  • Singh H, Garg R (2009) Effects of process parameters on material removal rate in WEDM. J Achiev Mater Manuf Eng 32(1):70–74

    Google Scholar 

  • Singh N, Kumar P, Goyal K (2014) Effect of two different cryogenic treated wires in wire electrical discharge machining of AISI D3 die steel. J Mech Eng 43(2):54–60

    Article  Google Scholar 

  • Singh V, Bhandari R, Yadav VK (2017) An experimental investigation on machining parameters of AISI D2 steel using WEDM. Int J Adv Manuf Technol 93(1–4):203–214

    Article  Google Scholar 

  • Va MK, Ab SB, Rc V, Md R (2010) Optimization of the WEDM parameters on machining Incoloy800 super alloy with multiple quality characteristics. Optimization 2(6):1538–1547

    Google Scholar 

  • Vikram Reddy V, Madar Valli P, Kumar A, Sridhar Reddy Ch (2015) Influence of process parameters on characteristics of electrical discharge machining of PH17-4 stainless steel. J Adv Manuf Syst 14:189–202

    Article  Google Scholar 

  • Zheng Z-P, Su H-C, Huang F-Y, Yan B-H (2007) The tool geometrical shape and pulse-off time of pulse voltage effects in a Pyrex glass electrochemical discharge microdrilling process. J Micromech Microeng 17(2):265

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Punjabi University, Patiala, 147002, India

    Tushar Saini & Khushdeep Goyal

  2. Department of Mechanical Engineering, Yadavindra College of Engineering, Talwandi Sabo, India

    Deepak Bhandari

Authors
  1. Tushar Saini
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Khushdeep Goyal
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Deepak Bhandari
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Khushdeep Goyal.

Ethics declarations

Conflict of interest

The authors have no conflict of interest and have not received any funding from any agency.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Saini, T., Goyal, K. & Bhandari, D. Multi-response optimization of WEDM parameters on machining 16MnCr5 alloy steel using Taguchi technique. Multiscale and Multidiscip. Model. Exp. and Des. 2, 35–47 (2019). https://doi.org/10.1007/s41939-018-0027-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s41939-018-0027-7

Keywords

Search

Navigation