Optimization of Micro Wire Electro Discharge Machining Process Parameters Using Aerospace Material

Abstract

The objective of this project is to investigate the performance of micro wire EDM machining of Al material. WEDM is extensively used in machining of conductive materials when accuracy and tight tolerance is important. Simple and easily understandable model for an axisymmetric 2D model for wire electric discharge machining (WEDM) has been developed using the finite element method (FEM). Correctness of the present FEA modeling method has been checked by comparing the present thermal modeling with the previously developed thermal model of INCONEL718 material. The observation have been influenced on various characteristics namely, material removal rate (MRR) and residual stress. Comparison was done between the theoretical MRR and the experimental results. Design was based on L9 orthogonal array that was taken by Taguchi design of experiment (DOE) approach with three-level, three factors Experiments have been conducted for each experimental run. Three principal component analysis (PCA) based optimization technique have been performed and each optimization results were discussed.