Materials Today: Proceedings xxx (xxxx) xxx

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Parametric optimization in wire EDM of D2 tool steel using Taguchi

method
Sahil Sharma a,⇑, Umesh Kumar Vates a, Amit Bansal b
a
Department of MAE, ASET, Amity University Uttar Pradesh, Noida, Uttar Pradesh, India
b
Department of Mechanical Engineering, IKGPTU, Kapurthala, Punjab, India

a r t i c l e i n f o a b s t r a c t

Article history: Wire EDM is a non-traditional machining method which is widely used for machining of extremely hard
Received 24 October 2019 material, and complex shapes which would not be possible using conventional machining methods. This
Received in revised form 20 February 2020 method of machining is widely practised in mould, tool and die industries. In this process, there is no
Accepted 24 February 2020
direct contact between the work piece material and wire electrode; therefore the hardness of work piece
Available online xxxx
material is not a bounding factor for the machining process. In this process, removal of material to be
done by producing a spark between the work piece material and the wire electrode. In the present work,
Keywords:
the machining of AISI D2 die steel of 13 mm diameter was performed using a 0.25 mm dia wire electrode.
Wire EDM
Taguchi method
The influence of various input process parameters (Ton, Toff, Ip, Tw) on the response characteristics
Analysis of variance (MRR, Ig, MT) was investigated by using Taguchi L9 orthogonal array. Signal to noise ratio and ANOVA
Machining parameters will also employed in the study of response parameters.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International
Conference on Advances in Materials Research – 2019.

1. Introduction and the choice of correct parameters is very important for the
advance processes of machining which influence the performance
Wire EDM is a non-conventional machining method which has characteristics. The major input factors like pulse on time (Ton),
been widely used to machine extremely hardened material, and pulse off time (Toff), gap voltage (Ig), duty factor, current, type of
complex shapes that would not be easy to machine with conven- dielectric, working time, polarity, powder size, density, and elec-
tional machining methods. It is mostly practised in mould, tool trode material have most influence on response characteristics like
and die making industries. In the late 1940s, in order to remove material removal rate (MRR), surface roughness (Ra), electrode
the material, discharge was made between the tool electrode and wear rate (EWR), wear ratio, and surface quality etc [4]. The selec-
machining material in the existence of fluid (dielectric) [1,2]. In tion of appropriate parameters may result in better surface finish,
this process, there is no absolute meeting of working material larger MRR and low tool abrasion rate. In the past few years,
and tool electrode, therefore hardness of work piece material has researchers have built up some better quality and modern opti-
no bounding factor in the process of machining. In this process, mization techniques like simulated annealing (SA), grey relation
removal of material was takes place through conductive material analysis, neural network, finite element method (FEM) and genetic
such as copper, tungsten or brass by producing a spark between algorithm (GA) to get the optimum machining parameters. Many
tool electrode and work piece material. Nowadays wire EDM researchers have made an attempt to purify the performance
become an essential machining process in the numerous jobs like parameters, but due to the involvement of number of variables
tool fabrication, die casting industries, automobiles, and aerospace and its complex nature it is not that much easy to utilize the full
industries etc. In the field of machining, various advance materials potential of this process.
are also used like ceramics, carbides and metal matrix composites Puertas et al. [5] examined role of input factors like Ton, Toff, and
[3]. WEDM process bind with various number of input parameters intensity for performing factors like dimensional precision and sur-
face quality. By using regression technique and factorial design of
experiments, the authors concluded that intensity has the maxi-
⇑ Corresponding author. mum influence on surface roughness. Lodhi and Agarwal [6] used
E-mail address: [email protected] (S. Sharma).

https://doi.org/10.1016/j.matpr.2020.02.802
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Materials Research – 2019.

Please cite this article as: S. Sharma, U. Kumar Vates and A. Bansal, Parametric optimization in wire EDM of D2 tool steel using Taguchi method, Materials
Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.802
2 S. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx

Nomenclature

Ton pulse on time GRA grey relational analysis

Toff pulse off time ANN artificial neural network
Ip peak current GA genetic algorithm
Tw wire tension ANOVA analysis of variance
MT machining time WEDM wire electrical discharge machining
MRR material removal rate WT wire tension
Ra surface roughness
EWR electrode wear rate

Taguchi L9 array for optimization of various input parameters like onal array DOE in EDM of Alloy-718 to inspect an effect of various
Ton, Toff, wire feed, and current throughout WEDM process of D3 controllable factors such as on time, voltage gap, peak current,
die steel; the study of ANOVA and Signal - Noise (S/N) fraction flush pressure, duty factor as well as different machining elec-
resulted that Ton and discharge current are high convincing param- trodes of graphite, brass and copper on machining performance
eters for surface roughness. Tosun and Cogun [7] also used Taguchi in terms of MRR, Ra, EWR and surface crack density (SCD). Recom-
approach to find out the influence of input parameters on the MRR mendation has been given through optimal results to use copper
and cutting width by wire EDM process on AISI 4140 tool steel. electrode for maximum MRR and minimal Ra, EWR and SCD. Same
Mahapatra and Patnaik [8] developed the optimized relationship approach has been developed by Upadhyay et al. [18] to find out
of rate of cutting, cutting width, and surface roughness by intro- appropriate input process parameters to satisfy amended response
ducing geometric algorithm and non-linear regression analysis in characteristics such as MRR, Ra, SCD and TWR. Surface inconsisten-
the wire EDM process of D2 die steel. Manjaiah et al. [9] study cies like crater wear, metal deposition layer, cracks etc also been
the influence of Ton, Toff, wire feed, and servo voltage on the MRR analyzed with SEM graphs.
and surface characteristics (Ra). Further the results were optimized
by using Taguchi method and concluded that servo voltage and Ton
2. Materials and methods
are high considerable factors which affect MRR and Ra. Ugrasen
et al. [10] done correlation of machining response between GMDH
2.1. Working material and wire electrode
technique by using molybdenum wire electrode in wire cutting of
402 grade steel. It was observed that GMDH technique for progno-
For performing the experiments, the D2 die material was
sis is better than collective analysis. Singh et al. [11] also developed
adopted as a working material in the form of round bar stock of
the inter-relationship of five machining factors (Ton, Toff, servo
diameter 13 mm. The round bar was further cut by using wire
voltage, peak current, wire feed) with five output parameters (cut-
EDM into similar pieces having thickness of 3 mm each for per-
ting rate, gap current, MRR, Ra and gap voltage) by taking AISI D2
forming the experimental study. The chemical distribution (wt%)
as a working material. Taguchi, ANOVA and Response surface tech-
of die steel material was determined by optical emission spectrom-
niques adopt to compare experimentation results which proved
eter (OEM) is mentioned in Table 1. Brass which is zinc coated was
Ton, Toff and voltage are high cogent factors which affects the cur-
used as a cutting or wire electrode having diameter of 0.25 mm.
rent rate and gap current. Pavani et al. [12] worked on EN-31 steel
The optical micrograph of the wire EDM setup and machined spec-
and performed experiments on WEDM to developed a model to
imen is shown in Fig. 1(a) and (b) respectively. The schematic dia-
correlate the machining process variables and performance charac-
gram of the machined specimen used in the present study is shown
teristics by adopting regression analysis and experimentation were
in Fig. 1(c).
done by using Taguchi (L27 orthogonal array) to figure out the best
possible parametric combination for MRR, tool abrasion rate and
Ra. Taguchi approach were also practiced by Thirumalai et al. 2.2. Conduct of experiments
[13] to optimize the various mechanical properties for a hybrid
epoxy based composite material. Various tests such as tensile, All the experiments have been performed by using Wire EDM
compressive and wear has also been performed to study the machine (Make: Electronica India Pvt 2.2.1. Ltd, Model: ELEKTRA
machinability of composite specimen. In an another study, Thiru- Sprintcut) as shown in Fig. 1a. For the conduction of experiments
malai et al. [14] used Taguchi optimization method to study the four machining factors like Ton, Toff, Ip, and Tw was selected to
impact of various machining factors on response characteristics established influence MRR, MT, and gap current (Ig).
such as flank wear and roughness of Ni based Inconel 718 super
alloy. Thirumalai and Senthilkumaar [15] used Taguchi L27 array 2.2.1. Pulse-on time
design of experiments in machining of Inconel 718 with carbide Ton is the duration of time at which machining is done. MRR is
tool to investigate an impact of input machining parameters such directly proportional to amount of energy applied during Ton.
as cutting speed, depth of cut and feed rate on various responses When the electrode polarities are reversed, longer pulses are found
such as MRR, Ra, life of tool, cutting force, consumption of power to produce higher MRR.
and flank wear. A significant machining factors has been selected
by adopting a technique of multi criteria decision making (MCDM) 2.2.2. Pulse-off time
and further optimized through a unique technique for order pref- Toff is the time duration at which re-ionization of dielectric
erence by similarity to ideal solution (TOPSIS). Tripathy and Tripa- takes place. More Toff means larger machining time. Pulse interval
thy [16] have reported the improved performance of quality will affect the speed and stability of the cut. In fact, shorter the
characteristics by using both multi objective techniques for pow- interval, faster will be the machining operation. But if the interval
der mixed EDM of H-11 die steel. Scanning electron microscope is too short, the ejected workpiece material will not be swept away
(SEM) images proved that surface topology is better with addition by the flow of dielectric. This will cause the next spark to be
of powder particles. Rahul et al. [17] also used Taguchi L27 orthog- unstable.

Please cite this article as: S. Sharma, U. Kumar Vates and A. Bansal, Parametric optimization in wire EDM of D2 tool steel using Taguchi method, Materials
Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.802
 S. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

Table 1
Chemical distribution of D2 tool steel.

Element C Si Mn Cr Mo Ni S
Composition (%) 1.6 0.3 0.38 12.3 0.7 0.23 0.016

Fig. 1. (a) Wire EDM (ELEKTRA Sprintcut). (b) Machined specimens. (c) Machined specimen with dimensions.

Table 2 2.2.4. Wire tension

Process parameters with different level values. Wire tension is a cogent factor in the machining process of Wire
Parameters Level 1st Level 2nd Level 3rd EDM. Less tension and slow speed lead to an increase in slit expan-
sion and the amplitude of vibrations in the wire. Wire tension has
Pulse-on time (A) 113 116 119
Pulse-off time (B) 30 35 40 the better influence on MRR. Due to an increase in Tw of WEDM
Peak current (C) 170 200 230 process, the discharge energy will get intensified and larger
Wire tension (D) 8 10 12 removal of rate material removal takes place
The MRR (mm3/min) was calculated by using the below men-
tioned formula.
2.2.3. Peak current Wi  Wf
During each pulse on time, the current increases until it reaches MRR ¼  1000
qt
a preset level, which is expressed as the peak current. An increase
in current, results in increased MRR as well as increased roughness where,
and tool wear rate. In die sinking and wire EDM applications, the W i = beginning weight of working material before machining
maximum amount of amperage is governed by the surface of the (g)
cut. W f = end weight of working material after machining (g)

Table 3
Taguchi L9 orthogonal array.

Exp. No. Process Parameter Performance Parameter

Ton (ms) Toff (ms) Ip (A) Tw MRR Ig MT
3
(mm /min) S/N ratio (A) S/N ratio (Min.) S/N ratio
1 113 30 170 8 69.348 36.8206 2.5 7.9588 6.18 15.8198
2 113 35 200 10 42.058 32.4769 2.0 6.0205 10.19 20.1635
3 113 40 230 12 40.048 32.0516 1.8 5.1054 11.35 21.0999
4 116 30 200 12 81.785 38.2534 2.1 6.4443 5.45 14.7279
5 116 35 230 8 69.318 36.8169 1.9 5.5750 6.37 16.0828
6 116 40 170 10 39.424 31.9152 1.7 4.6089 11.20 20.9844
7 119 30 230 10 82.534 38.3326 2.0 6.0205 5.35 14.5671
8 119 35 170 12 70.083 36.9122 1.6 4.0823 6.30 15.9868
9 119 40 200 8 58.796 35.3869 1.3 2.2788 7.51 17.5128

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4 S. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx

whereas ‘‘smaller-the-better” were used for time taken for machin-

ing as shown in Eqs. (1) & (2) respectively.
For higher the better:

ðS=NÞHB ¼ 10 log ðMSDÞHB ð1Þ

PR
where, ðMSDÞHB ¼ R 1 1
i¼1 Y 2
i

Fig. 2. Effect of Input parameters on MRR (Mean and S/N data).

t = time of machining (min)

q = density of D2 die steel (7.70 g/cm3)
Selected input parameters studied at three levels are mentioned
in the Table 2. Experimental data has been performed depends on
Taguchi L9 technique as shown in Table 3 and further analysed by
using ANOVA method. L9 orthogonal array might be the best pos-
sible option because it is meant to examined the influence of four
independent variables with three factor level values. Further, in the
present study, it is also assumed that between any two factors
there is no interaction. The ‘‘larger-the-better” characteristic
selected to find values of S/N ratio for gap current and MRR, Fig. 3. Effect of Input parameters on Ig (Mean and S/N data).

Table 4
Response Table for S/N Ratio and for means (MRR).

Level S/N ratio Raw Data

Ton Toff Ip Tw Ton Toff Ip Tw
1 33.78 37.80 35.22 36.34 50.48 77.89 59.62 65.82
2 35.66 35.40 35.37 34.24 63.51 60.49 60.88 54.67
3 36.88 33.12 35.73 35.74 70.47 46.09 63.97 63.97
Delta 3.09 4.68 0.52 2.10 19.99 31.80 4.35 11.15
Rank 2 1 4 3 2 1 4 3

Table 5
ANOVA table for MRR.

Source DOF Sum of squares Mean square F -value P -value % contribution

Pulse on time 2 14.58 7.291 1.08 0.396 26.54
Pulse off time 2 32.92 16.460 4.49 0.064 59.92
Peak current 2 0.4230 0.2115 0.02 0.977 0.77
Wire tension 2 7.015 3.507 0.44 0.664 12.77
Total 8 54.938

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 S. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx 5

Table 6
Response Table for S/N Ratio and for means (Gap current).

Level S/N ratio Raw Data

Ton Toff Ip Tw Ton Toff Ip Tw
1 6.362 6.808 5.550 5.271 2.100 2.200 1.933 1.900
2 5.543 5.226 4.915 5.550 1.900 1.833 1.800 1.900
3 4.127 3.998 5.567 5.211 1.633 1.600 1.900 1.833
Delta 2.234 2.810 0.652 0.339 0.467 0.600 0.133 0.067
Rank 2 1 3 4 2 1 3 4

Table 7
ANOVA table for Gap current (Ig).

Source DOF Sum of squares Mean square F-value P-value % contribution

Pulse on time 2 7.667 3.833 1.78 0.248 37.21
Pulse off time 2 11.908 5.954 4.11 0.075 57.80
Peak current 2 0.8298 0.4149 0.13 0.884 4.03
Wire tension 2 0.1966 0.09832 0.03 0.972 0.95
Total 8 20.6014

For lower the better: S/N ratio for all three levels of machining parameters. A1, B1, C3
and D2 were the best possible combination in the process of
ðS=NÞLB ¼ 10 log ðMSDÞLB ð2Þ
machining. The calculation of ranks in response Table 6 greatly
R 
P  helps to identify which parameter have the most influence on
where, ðMSDÞLB ¼ 1R Y 2i and Y i = response value.
i¼1

3. Result and discussion

3.1. Influence of input factors on MRR

Experiments were performed by using Taguchi L9 technique to

see the influence of various input factors (Ton, Tw, Ip) on the MRR.
According to the graph plotted by using Minitab17 software
(Fig. 2), it has been observed that the value of MRR for Ton initially
decreases and further increases in the third level. Value of MRR
constantly reduces with an accession in the level of Toff. It also
increases by increasing level of peak current (Ip). With rise in the
wire tension, a slight difference has been observed between initial
and final level value of MRR and a huge drop in middle level value
was observed. Rank and delta values display that Toff has most
influence on the MRR chased by Ton, Tw and Ip. Table 4 and Fig. 2
indicated the influence of various control parameters as well as
the optimal levels. The S/N ratios revealed that with greater differ-
ences between level values, greater values are better to achieve
significance. Therefore, the control factors with the largest S/N
ratio value shows the best optimal combination of parameters
for machining. For MRR, S/N response graph indicates that the opti-
mal combination of wire EDM parameters would be A3, B1, C3, and
D1. ANOVA technique performed to study the significance of input
factors towards MRR and it is clearly seen in Table 5 that the Toff
has high contribution (59.92%) in the process of machining.

3.2. Influence of input factors on Ig

The influence of various input factors (Ton, Tw, Ip) on the Ig was
investigated by using Taguchi L9 technique. It has been observed
from Fig. 3 that, the gap current (Ig) constantly decreases with an
accession in a levels of both on time (Ton) and off time (Toff). There
is no such difference has been observed in the initial and final level
values of gap current but it reduces in the second level. Fig. 3
shows no such effect of wire tension on values of gap current.
Response table for gap current (Table 6) provide the values of Fig. 4. Effect of Input parameters on MT (Mean and S/N data).

Please cite this article as: S. Sharma, U. Kumar Vates and A. Bansal, Parametric optimization in wire EDM of D2 tool steel using Taguchi method, Materials
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6 S. Sharma et al. / Materials Today: Proceedings xxx (xxxx) xxx

Table 8
Response Table for S/N Ratio and for means (Machining time).

Level S/N ratio Raw Data

Ton Toff Ip Tw Ton Toff Ip Tw
1 19.03 15.04 17.60 16.47 9.240 5.660 7.893 6.687
2 17.27 17.41 17.47 18.57 7.673 7.620 7.717 8.913
3 16.02 19.87 17.25 17.27 6.387 10.020 7.690 7.700
Delta 3.01 4.83 0.35 2.10 2.853 4.360 0.203 2.227
Rank 2 1 4 3 2 1 4 3

Table 9
ANOVA table for Machining time.

Source DOF Sum of squares Mean square F-value P-value % contribution

Pulse on time 2 13.68 6.842 0.98 0.428 24.63
Pulse off time 2 34.96 17.480 5.09 0.051 62.91
Peak current 2 0.1847 0.09233 0.01 0.990 0.33
Wire tension 2 6.739 3.370 0.41 0.679 12.13
Total 8 55.5637

machining characteristics. ANOVA results (Table 7) revealed that Declaration of Competing Interest
Toff has most influencing factor (contributing 57.80%) chased by
Ton (37.21%), Ip (4.03%), Tw (0.95%). The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
3.3. Influence of input parameters on MT

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