OPTIMISATION OF WIRE-EDM PROCESS PARAMETERS FOR ACHIEVING LOW SURFACE ROUGHNESS IN MACHINING OF IS 5986 FE 410 STEEL AND REGRESSION MODELLING

摘要

Non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters namely current (I_c), pulse-on time(T_(on)), pulse-off time (T_(off)), wire-speed (W_s) and voltage (I_v) on surface roughness (SR) is investigated while machining non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters namely current (I_c), pulse-on time(Ton), pulse-off time (T_(off)), wire-speed (W_s) and voltage (I_v) on surface roughness (SR) is investigated while machining of IS 5986 FE 410 steel by wire-electrical discharge machine (wire-EDM). The experiments were designed using Taguchi L16 arrays and results are analyzed using statistical methods. The process parameters such as I_c, T_(off) and W_s showed a significant contribution by 66.22%, 13.77% and 9.25% respectively on SR. Further, the process parameters were optimized to obtain a minimum SR which produced in Ra values 1.480 μm at settings I_c-4 A, T_(on)- 40 μs, Ton - 10 μs, W_s- 1400 rpm and I_v- 80 V. Regression model is developed to predict the SR at different settings for the control parameters which predicted the response with average predication an error of 11.08%.