Parameters Optimization of Copper Powder Mixed Dielectric and Pure Dielectric Medium in Wire Electrical Discharge Machining of AISI D3 Steel

摘要

Wire Electrical Discharge Machining (Wire-EDM) is a sophisticated machining process to machine harder conductive materials with greater accuracy and precision. This research aims to find the optimal parameter for machining of AISI D3 steel which is also referred to as High Carbon High Chromium steel (HCHCr). The experiments are carried out with pulse-on time, pulse-off time, current and voltage as input variables. Two different thickness of work material 50 mm and 75 mm were machined using demineralized water with and without copper powder as dielectric medium. The effect of demineralized water with and without copper powder on the response variables such as material removal rate (MRR) and surface roughness (Rq) were studied in detail. The experiments were conducted on Taguchi's L18 orthogonal array (OA). Analysis of the obtained experimental data are carried out using Minitab 16. Signal-to-Noise ratio are derived. Besides Taguchi optimization technique, combined objective function (Minimization) is adopted to find the common optimal input parameter. This research makes an ardent attempt to conclude that the demineralized water with copper powder when used as dielectric gives higher MRR and balanced Rq and optimum parameters for 50 mm and for 75 mm workpiece are reported.