Optimization of the Process Parameters of Wire Edm of A Hardened Steel 60hrc Component by Taguchi Based Design of Experiments

Abstract

The Machining parameters tables provided by the machine tool manufacturers often do not meet the operator requirements and sometimes even do not even provide efficient guidelines to manufacturing engineers. Hence, a suitable selection of machining parameters of CNC wire cut electrical discharge machining (EDM) process is necessary.

In this project work we perform an experimental investigation to determine the parameters setting during the machining of Hardened  steel 60HRC. The Taguchi method, a powerful tool for experimental design, is used to optimize the CNC-wire cut-EDM parameters. According to the Taguchi quality design Concept, a L₉ (3⁴)orthogonal array was used to determine the S/N ratio, and an analysis of variance (ANOVA) and the F-test values were used to indicate the significant machining parameters affecting the machining performance.

From experimental results and through ANOVA and F-test values, the significant factors are determined for each machining performance criteria, such as the metal removal rate, surface roughness, Cylindricity and spark gap (gap width). Considering these significant CNC wire cut-EDM parameters, verification of the improvement in the quality characteristics for machining Hardened steel 60HRC was made with a confirmation test with respect to the

chosen initial or reference parameter setting. Mathematical models relating to the machining performance are established using the linear regression for the effective machining of Hardened steel 60HRC. The determined optimal combination of CNC-wire cut- EDM parameters obtained from the study satisfy the real requirement of quality machining of Hardened steel 60HRC in practice.