Experimental Analysis of WEDM for Enhanced MRR and Surface Finish in Mild Steel
Lakki Rathore, Joji Thomas, S P Shrivas, Nitin Nayak
ABSTRACT
An experimental investigation was conducted to identify the key WEDM parameters influencing material removal rate (MRR) and surface roughness (SR) in machining mild steel. MRR is a critical factor determining productivity and machining economy, while SR represents the quality of the machined surface. Therefore, selecting appropriate process parameters is essential to achieve both high productivity and superior surface finish. In rough cutting operations, the primary objective is to maximize MRR while minimizing SR to ensure better performance. In this study, discharge current, pulse-on time, pulse-off time, and servo feed were chosen as control parameters. Each parameter was considered at three levels, and experiments were designed using a Taguchi L27 orthogonal array. The significance of these parameters on output responses was analyzed using Analysis of Variance (ANOVA). Furthermore, the relationship between process parameters and responses was modeled using non-linear regression analysis. The developed models were tested and confirmed for adequacy, ensuring their reliability in predicting machining performance.
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