1

Table of Contents
CHAPTER 1 ................................................................................................................................................. 3
INTRODUCTION .................................................................................................................................... 3
1.1 Background of Study ................................................................................................................ 3
1.2 Term/Concept ................................................................................................................................. 4
1.3 Problem Statement .......................................................................................................................... 8
1.4 Objective ......................................................................................................................................... 8
1.5 Scope of Project .............................................................................................................................. 9
1.6 Significant of Project ...................................................................................................................... 9
1.7 Summary ......................................................................................................................................... 9
CHAPTER 2 ............................................................................................................................................... 10
LITERATURE REVIEW ....................................................................................................................... 10
2.1 Introduction ................................................................................................................................... 10
2.2 Review of journals ........................................................................................................................ 10
2.3 Gaps in Literature Review ............................................................................................................ 17
CHAPTER 3 ............................................................................................................................................... 18
METHODOLOGY ................................................................................................................................. 18
3.1 Introduction ................................................................................................................................... 18
3.2 Gathering Information................................................................................................................... 19
3.3 Material preparation ...................................................................................................................... 20
3.4 Selection of the machining parameter (factor) and their level ...................................................... 22
3.5 Design of experiment .................................................................................................................... 23
3.6 Specimen preparation .................................................................................................................... 26
3.7 Constant machining parameters use in the cutting process ........................................................... 26
3.8 Measurement test and analysis Methodology ............................................................................... 28
3.9 Taguchi method....................................................................................................................... 29
3.10 Experimental and measurement equipment ................................................................................ 31
CHAPTER 4 ............................................................................................................................................... 34
EXPERIMENTAL RESULTS AND ANALYSIS: TAGUCHI METHOD ........................................... 34
2

4.1 Introduction ................................................................................................................................... 34
4.2 Data Collection ............................................................................................................................. 35
CHAPTER 5 ............................................................................................................................................... 50
DISCUSSION ......................................................................................................................................... 50
CHAPTER 6 ............................................................................................................................................... 52
CONCLUSION ....................................................................................................................................... 52
6.1 Introduction ................................................................................................................................... 52
6.2 Conclusions ................................................................................................................................... 52
REFERENCES ....................................................................................................................................... 53














3





CHAPTER 1



INTRODUCTION

1.1 Background of Study

Wire electrical discharge machining (WEDM) is a spark erosion process used to
produce complex two-dimensional and three-dimensional shapes through electrically
conductive work pieces by using wire electrode. The sparks will be generated between
the work piece and a wire electrode flushed with or immersed in a dielectric fluid [1].
In wire electrical discharge machining, (WEDM), the process parameters will
ensure whether the product produce is as required or not which is the product is high
accuracy and fine resultant surface finish[2]. In this study, the process parameters that
will considered are pulse-off time (T
off
), peak current (IP), wire feed (WF) and wire
tension (WT).
In this study, efforts are to estimate cutting rate (CR) metal removal rate (MRR)
and surface finish (SF) using experimental data follow by develop prediction models
4

using Taguchi Method approach. The adequacy of the above the proposed models have
been tested through the analysis of variance (ANOVA). Optimal combination of these
parameters was obtained for achieving controlled WEDM of the work pieces.
1.2 Term/Concept
1.2.1 Electric Discharge Machining (EDM)

Electric discharge machining (EDM), also referred to as die sinking spark
machining, wire erosion, or spark eroding. It is a manufacturing process by using
electrical discharges (sparks) to obtain the desired shape.[3] Parent metal is removed
from the work piece by a series of swiftly frequent current discharges between
two electrodes, separated by a dielectric liquid and focus to an electric voltage. One of
the electrodes is the tool-electrode, while the other is the work piece-electrode.
The intensity of the electric field in the volume between the electrodes becomes
greater than the strength of the dielectric, which breaks, allowing current to flow between
the two electrodes when the distance between the two electrodes is reduced. Thus, the
specimen is removed from both the electrodes. When the current flow stops, new liquid
dielectric is usually conveyed into the inter-electrode volume enabling the solid particles
to be carried away and the insulating properties of the dielectric to be restored. Flushing
is the term by referring the adding new liquid dielectric in the inter-electrode. Also,
a difference of potential between the two electrodes is restored to what it was before the
breakdown after a current flow, so that the breakdown of a new liquid dielectric can
occur.

1.2.2 Wire Electric Discharge Machining (WEDM) process

The material removal mechanism of WEDM is involving the erosion effect
produced by the electrical discharges (sparks) which is very similar to the EDM process.
Material is eroded from the work piece by a series of discrete sparks occurring between
the work piece and the wire separated by a stream of dielectric fluid, which is
5

continuously fed to the machining zone [4]. However, today's WEDM process is
commonly conducted on work pieces that are totally submerged in a tank filled with
dielectric fluid. Such sank method of WEDM endorses temperature stabilization and
efficient flushing especially in cases where the work piece has varying thickness. The
WEDM process makes use of electrical energy generating a channel of plasma between
the anode and cathode, and turns it into thermal energy at a temperature in the range of
8000 -12,000 C or as high as 20,000 C initializing a substantial amount of heating and
melting of material on the surface of each pole. When the pulsating direct current power
supply occurring between 20,000 and 30,000 Hz is turned off, the plasma channel breaks
down [5]. This causes a sudden reduction in the temperature allowing the circulating
dielectric fluid to implore the plasma channel and flush the molten particles from the pole
surfaces in the form of microscopic debris. While the material removal mechanisms of
WEDM and EDM are similar, their functional characteristics are not identical. WEDM
uses a thin wire continuously feeding through the work piece by a microprocessor, which
enable parts of complex shapes to be machined with exceptional high accuracy [6]. A
varying degree of taper ranging from ISO for a 100 mm thick to 30" for a 400 mm thick
work piece can also be obtained on the cut surface. The microprocessor also constantly
maintains the gap between the wire and the work piece, which varies from 0.025 to
0.05mm [7]. WEDM eliminates the need for elaborate pre-shaped electrodes, which are
commonly required in EDM to perform the roughing and finishing operations [7]. In the
case of WEDM, the wire has to make several machining passes along the profile to be
machined to attain the required dimensional accuracy and surface finish (SF) quality.




6



1.2.3 Material Removal Rate (MRR)

The machining performance evaluation are using material removal rate (MRR).
When electrodes were used with positive polarity in all cases of semi-sintered electrodes,
the MRR increased. By using EDM-C3 with positive polarity the highest MRR and
minimal wear were obtained. The copper electrode gave the highest electrode wear ratio.
The results of electrode wear ratio relate to melting point which is materials with higher
melting points wear less [8]. However, the wear ratio is inversely proportional to the
MRR result [8]. In the case of lower MRR, the electrode must spend more time to
achieve machining. The positive polarity gives better MRR than negative polarity [8].
This result is the same as for EDM on a conductive material [8]. This can be explained by
the fact that positive polarity gives better machining by causing a higher MRR under
higher discharge energy [8].



7

1.2.4 Surface finish (SF)

Product designers always determined to design machinery that can run faster, last
longer, and operate more accurately than ever. Modern development of high speed
machines has resulted in increased speeds of moving parts and higher loading. Most
manufacturing processes produce parts with surfaces that are either unsatisfactory from
the standpoint of geometrical surface and to correct specific irregularities and so must be
applied carefully to a given production sequence. Each process is a final operation in the
machining sequence for a precision part and is commonly preceded by conventional
grinding [9]. This primer begins by explaining how industry controls and measures the
precise degree of smoothness and roughness of a finished surface.

1.2.5 Cutting rate (CR)

The rate at which the cutting tool and the work piece move in relation to one
another. In the present study, cutting rate is a measure of job cutting which is digitally
displayed on the screen of the machine and is given quantitatively in mm/min.

1.2.6 Titanium Alloy (Ti 6Al 4V)

Pure titanium undergoes an allotropic transformation from the hexagonal close-
packed alpha phase to the body-centered cubic beta phase at a temperature of 882.5C
(1620.5F). Alloying elements can act to stabilize either the alpha or beta phase. Through
the use of alloying additions, the beta phase can be sufficiently stabilized to coexist with
alpha at room temperature. This fact forms the basis for creation of titanium alloys that
can be strengthened by heat treating. Titanium alloys are generally classified into three
main categories: Alpha alloys, which contain neutral alloying elements (such as Sn)
and/or alpha stabilizers (such as Al, O) only and are not heat treatable; Alpha + beta
alloys, which generally contain a combination of alpha and beta stabilizers and are heat
8

treatable to various degrees; and Beta alloys, which are metastable and contain sufficient
beta stabilizers (such as Mo, V) to completely retain the beta phase upon quenching, and
can be solution treated and aged to achieve significant increases in strength [10]. Ti 6Al-
4V is known as the "workhorse" of the titanium industry because it is by far the most
common Ti alloy, accounting for more than 50% of total titanium usage. It is an alpha +
beta alloy that is heat treatable to achieve moderate increases in strength [11]. Ti 6Al-4V
is recommended for use at service temperatures up to approximately 350C (660F) . Ti
6Al-4V offers a combination of high strength, light weight, formability and corrosion
resistance which have made it a world standard in aerospace applications [10].

1.3 Problem Statement

If the cutting process by WEDM machine is not in optimum parametric, the
product or the component required the heavy grinding and polishing process. If the
optimal parameters are not predicted, the technician also has to waste time to get the
optimal parameters. Due to the problems, it will waste time to produce the product and
component at once wasting the cost to hire the labor for overtime.

1.4 Objective

The wire-cut electrical discharge machining is commonly used in aerospace,
ordinance, automobile and general engineering industries to obtain intricate and complex
shapes [12]. Moreover machine tool tables provided by the manufacturer often do not
meet the requirements in machining for particular material [12]. So, to obtain various
shapes of structural components the wire-cut EDM process and improving the machining
efficiency which is produce the product that have lowest surface roughness it requires the
models to predict optimum parametric combinations accurately[12].

9

1.5 Scope of Project

The scope of the project is more to predict the optimum parametric for the
Titanium alloys [13]. The work piece will be cut and the surface roughness will be
measure.


1.6 Significant of Project

One of significant of this study is facilitate the engineers work which is engineer
no need to measure the WEDM parameters for cutting the titanium alloy anymore.
Engineers only just refer to this study. It is at once shortening the time-to-market for the
products or components [14]. Because of that, the company can save the time and cost.

1.7 Summary

This research consists of six chapters. Chapter 1 is the introduction about this
study which has been discussed briefly about project background, problem statement,
objective, scope of project and significant of project. This chapter is the fundamental for
the project and the guidelines for this research. Chapter 2 is the literature review which
discusses methods and findings previously done by other people which are related to the
study. Chapter 3 is the Methodology which explains the approaches and methods used in
performing the research. Chapter 4 is the chapter which reports the outcomes or results of
this research. Chapter 5 is the discussion from the project. The chapter 6 consists of the
recommendation and the chapter 7 is the conclusion of the research.




10





CHAPTER 2



LITERATURE REVIEW

2.1 Introduction

Literature review is one of the scope studies for this research. It works as guide to
run this experiment for this research. It will give part in order to get the information about
wire electrical discharge machine (WEDM) and will give idea to run the experiment.
From the early stage of the project, a variety of literature studies have been done.
Research journals, printed or online conference article were the main source in the project
guides. This part will include almost entire of the operation including the history, test,
machining properties and results.

2.2 Review of journals

The wire-cut electrical discharge machining (WEDM) is commonly used in
aerospace, ordinance, automobile and general engineering industries. For this study, the
11

several journals that I analyze have the same objective with this study which is determine
appropriate machining parameters to improve surface quality. The conclusion of the
entire journal proved that, peak current (IP) and pulse duration are the most significant
parameters. The investigating of the viability and dependability of the magnetic rough
media for finishing machined surface had proved that the magnetic force assisted EDM
had a better machining stability, since the wreckage driven by the assisted magnetic force
would be expelled more quickly and completely to reduce abnormal discharge. [14]
Investigation the effect of machining parameters on kerf statistically in WEDM had
proved that the highly effective parameters on both the kerf and the MRR were found as
open circuit voltage and pulse duration, while wire speed and dielectric flushing pressure
were less effective factors. [1] To present an efficient method by means of which to
determine appropriate machining parameters so as to be able to achieve the objective of
the shortest machining time whilst at the same time satisfying the requirements of
accuracy and surface roughness. It is found the table feed and pulse-on time have a
significant influence on the metal removal rate, the gap voltage and the total discharge
frequency, whilst the gap width and the surface roughness are mainly influenced by the
pulse-on time. [15] Modeling the machining parameters of wire electrical discharge
machining of Inconel 601 using Response Surface Methodology (RSM) study has proved
its adequacy to machine Inconel 601 material under acceptable volumetric material
removal rate which reached 8 mm
3
/min and surface finish (R
a
) less than 1m.[2] On the
research of to predict the optimum parametric combination accurately due to improve the
machining efficiency, it is found that, the parameters IP and T
ON
have the most significant
effect on surface roughness due to the fact that the energy content of a single spark
discharge can be expressed as a product of T
ON
and IP known as discharge energy.[12]





12

Table 2.1: Journals Comparison
No Author and Title Description Finding
1
Y.S. Liao, J.T.
Huang, Y.H.
Chen A study to
achieve a fine
surface finish in
Wire-EDM
The objectives of this research are:
1. To obtain a fine surface.
2. To improve surface quality and
achieve an optimal surface
roughness in finishing process
This research is considering those
controlling factors:
1. Pulse-generating circuit (PS)
2. Conductivity of the dielectric
(K)
3. Resistance in the circuit (R)
4. Capacitance in the circuit (C)
5. Applied voltage (V)
6. Feed rate of the table (F)
7. Pulse-off time (T
off
)
8. Error, e
A dc pulse-
generating circuit
of positive polarity
(wire electrode is
set as anode) can
achieve a better
surface roughness
in finishing
operation.
2
Yan-Cherng Lin,
Yuan-Feng Chen,
Der-An Wang,
Ho-Shiun Lee
Optimization of
machining
parameters in
magnetic force
assisted EDM
based on Taguchi
Method.
The investigating of the feasibility and
reliability of the magnetic abrasive
media for finishing machined surface.
The control parameters:
1. Machining polarity (P)
2. Peak current (I
P
)
3. Auxiliary current with high
voltage (I
H
)
4. Pulse duration (
P
)
5. No-load voltage (V)
6. Servo reference voltage (S
V
)
By using Taguchi method: 6 factors, 3
The magnetic force
assisted EDM had a
better machining
stability, since the
wreckage driven by
the assisted
magnetic force
would be expelled
more quickly and
completely to
reduce abnormal
discharge.
13

levels = L18
Work piece SKD 61 steel
Electrode electrolytic copper
3
Nihat Tosun, Can
Cogun, Gul
Tosun A study
on kerf and
material removal
rate in wire
electrical
discharge
machining based
on Taguchi
method.
Investigate the effect of machining
parameters on kerf statistically in
WEDM.
The controlling parameters:
1. Open circuit voltage (V)
2. Pulse duration (s)
3. Wire speed (m/min)
4. Flushing pressure (kg/cm
2
)
By using Taguchi method: 4 factors, 3
levels = L18
Work piece AISI 4140 steel (DIN
42CrMo4)
Electrode CuZn37 Master brass wire
Finding the
highly effective
parameters on both
the kerf and the
MRR were found as
open circuit voltage
and pulse duration,
whereas wire speed
and dielectric
flushing pressure
were less effective
factors.
4
Y.S. Liao, J.T.
Huang, H.C. Su
A study on the
machining-
parameters
optimization of
wire electrical
discharge
machining.
To present an efficient method by
means of which to determine
appropriate machining parameters so as
to be able to achieve the objective of
the shortest machining time whilst at
the same time satisfying the
requirements of accuracy and surface
roughness.
The controlling parameters:
1. Table feed
2. Pulse-on time
3. Pulse-off time
4. Wire speed
5. Wire tension
6. Flushing
Finding it is
found the table feed
and pulse-on time
have a significant
influence on the
metal removal rate,
the gap voltage and
the total discharge
frequency, whilst
the gap width and
the surface
roughness are
mainly influenced
by the pulse-on
time.
14

By using Taguchi method : 6 factors, 3
levels = L18
Work piece SKD11 alloy steels
Electrode brass wire
5
M.S. Hewidy,
T.A. El-Taweel,
M.F.Safty
Modelling the
machining
parameters of
wire electrical
discharge
machining of
Inconel 601 using
RSM
The objective of the mathematical
models is to achieve higher machining
productivity with a desired accuracy
and surface finish.
Process parameters :
1. Peak current (I
P
)
2. Duty factor
3. Wire tension
4. Water pressure
By using RSM = 31 no of experiments
Work piece Inconel 601
Electrode Brass CuZn377
Finding WEDM
has proved its
adequacy to
machine Inconel
601 material under
acceptable
volumetric material
removal rate which
reached 8 mm
3
/min
and surface finish
(R
a
) less than 1m.
6
Pujari Srinivasa
Rao, Beela
Satyanarayana,
Koona Ramji
Effect of WEDM
conditions on
surface roughness
: A parametric
optimization
using Taguchi
method.
The objective of this research is to
predict the optimum parametric
combination accurately due to improve
the machining efficiency.
The controlling parameters:
1. Pulse-on time
2. Pulse-off time
3. Peak current
4. Flushing pressure of dielectric
fluid
5. Wire feed rate setting
6. Wire tension setting
7. Spark gap voltage setting
8. Servo feed setting
Taguchi method 7 factors, 3 level =
From the ANOVA
and S/N ratio
calculations, it is
found that, the
parameters IP and
T
ON
have the most
significant effect on
surface roughness
due to the fact that
the energy content
of a single spark
discharge can be
expressed as a
product of T
ON
and
IP known as
15

L18
Work piece Aluminium-24345
discharge energy
7
Muthu Kumar,
Suresh Babu,
Venkatasamy and
Raajenthiren
Optimization of
the WEDM
parameters on
machining
Incoloy800 Super
alloy with
Multiple Quality
Characteristics
Investigation of the multi-response
optimization of WEDM process for
machining Incoloy 800 using
combination of Grey Relational
analysis and Taguchi method to achieve
higher Material Removal Rate (MRR),
lower surface roughness (Ra) and Kerf
width (k).
The controlling parameters :
1. Gap voltage
2. Pulse-on time
3. Pulse-off time
4. Wire feed
Work piece Incoloy800
Electrode brass wire
By using Grey Taguchi method 4
factors, 3 levels = L9
The optimal
process parameters
based on Grey
Relational Analysis
for the Wire-Cut
EDM of
Incoloy800 include
a 50 V gap voltage,
10 s pulse-on
time, 6 s pulse-off
time and 8
mm/minute Wire
Feed rate.
8
H. Singh, R. Garg
Effects of
process
parameters on
material removal
rate in WEDM
Investigations to reveal the process
parameters impact on material removal
rate of hot die steel (H-11)
Controlling parameters :
1. Pulse-on time
2. Pulse-off time
3. Spark gap set voltage
4. Peak current
5. Wire feed
6. Wire tension
Work piece hot die steel H-11
Electrode brass wire
The finding is the
material removal
rate (MRR) directly
increase in pulse-on
time (T
ON
) and peak
curent (IP) while
decreases with
increase in pulse-
off time (T
OFF
) and
servo voltage (SV).
16

By using one factor at a time approach.
9
Anish Kumar,
Vinod Kumar,
Jatinder Kumar
Prediction of
surface roughness
in wire electric
discharge
machining
(WEDM) process
based on
Response Surface
Methodology.
The objective of this study is the
investigation of pulse-on time, pulse-
off time, peak current, spark gap
voltage, wire feed and wire tension
effect on surface roughness.
Controlling parameters :
1. pulse-on time
2. pulse-off time
3. peak current
4. spark gap voltage
5. wire feed
6. wire tension
work piece pure titanium (grade-2)
electrode brass wire
RSM method = 54 experiments order

The surface
roughness was
ranged from
2.48m to 2.62m
during WEDM of
pure titanium. The
minimum surface
roughness was
obtained for the
process parameter
combination given
by Ton=112s,
Toff=56s,
Ip=120A, SV=60V,
WF = 7m/min and
WT = 980 grams.
The percentage
contribution of
input parameters
given by Ton: 55%,
Toff: 28%, Ip: 8%,
SV: 6% and error:
3%.

10
R.
Ramakrishnan,
L.
Karunamoorthy
Modeling and
To predict the performance
characteristic namely material removal
rate and surface roughness, artificial
neural network models were developed
using back-propagation algorithms.
By an increase of
pulse on time and
ignition current, the
effect of MRR was
improved. But at
17

multi-response
optimization of
Inconel 718 on
machining on
machining of
CNC WEDM
process.
Controlling parameters :
1) Pulse-on time
2) Pulse-off time
3) Wire feed speed
4) Ignition current
Work piece Inconel 718
Electrode brass wire
By using Taguchi method 4 factors, 3
levels =L9
higher rates of
pulse on time and
ignition current the
surface quality of
the work specimen
was affected.


2.3 Gaps in Literature Review

After a comprehensive study of the existing literature, a number of gaps have been
observed in machining of WEDM.
The previous researchers have investigated effect of other process parameters on
the performance measures of the specimen.
The effects of machining parameters on hot working titanium alloy Ti 6A 4Al
has not been explored using WEDM with brass wire as electrode.








18





CHAPTER 3



METHODOLOGY

3.1 Introduction

Current chapter generally discusses methodology of the project, with a focus on
electric discharge machine (EDM) experiment and machining. Pertinent data collection is
done in order for further research analysis in next chapter. This chapter contains the
methodology to conduct this study. Methodology involves Design of Experiment (DOE),
the problem identification and solving, and detail experimental design. This project
consists of two semesters. The proposal, literature review and methodology planning
were conducted in semester 1 of this project. It is also including the study of electric
discharge machine (EDM). The semester two concludes the preparation of work pieces
and experimental tools, running experiment, and get data collection do the analysis.



19

3.2 Gathering Information



















Flow chart 3.1: The investigation flow
Start
End
Topic discussion
Literature review
Survey for material and equipment

Propose the experimental design

Determine test condition

Run the experiment

Analyze the result
Main effect plot, best parameters
Confirmation test
20

3.3 Material preparation

The most important thing is material selection to this experiment because
different materials have different working parameters depending on their properties. In
processes related to the EDM the right selection of the machining material is also the
most important aspect to take into consideration. From the observation at the workshop in
Mechanical Engineering Faculty in UiTM Shah Alam and discussion with partner and
supervisor, the work piece that has been selected is Titanium Alloy (Ti 6Al 4V) while the
wire electrode is brass wire.

3.3.1 Work piece material

The work piece material was titanium alloy (Ti 6Al 4V) and its dimensions were
6mm x 5mm x 50mm. Titanium alloy (Ti 6Al 4V) have the low weight ratio high
strength, and outstanding corrosion resistance inherent. In order that, it is has led to a
wide and diversified range of successful applications which demand high levels of
reliable performance in automotive, power generation, aerospace, oil and gas extraction,
and other major industries. In the majority of these and other engineering applications
titanium has replaced heavier, less practical or less cost effective materials. Reliable,
economic and tougher systems and components should be taken into account in designing
with titanium, which in many situations have considerably exceeded performance and
service life prospect. Titanium is available in several different grades.

21


Figure 3.1: Titanium Alloy Ti 6Al 4V
3.3.2 Wire Electrode

The electrode material was brass wire which is the most common material of tool
electrode used in WEDM industries. The electrode front face was 0.25 mm diameter.

Figure 3.2: Brass Wire

22

3.4 Selection of the machining parameter (factor) and their level

According to Taguchi method, L27 mixed orthogonal arrays table was chosen for
the experiments. The four factors chosen are pulse-off time, wire feed, wire tension and
peak current. Each parameter was designed to have three levels.

Table 3.1: Parameters and Their Levels
PARAMETER
LEVEL
L1 L2 L3
Pulse-off time 1 3 5
Peak current 8 9 10
Wire tension 8 9 10
Wire feed 8 9 10

3.4.1 Pulse off Time

The pulse off time is referred as T
off
and it represents the duration of time in
between the two simultaneous sparks. The voltage is not present during this part of the
cycle. The T
off
setting time range available on the machine tool is 1-5 which is applied in
steps of 2 units. With a lower value of T
off
, there is more number of discharges in a given
time which is resulting in increase in the sparking efficiency. As a result, the cutting rate
also increases. The wire breakage may occur by using very low values of T
off
period,
which in turn reduces the cutting efficiency. As and when the discharge conditions
become unstable, the T
off
period can be increase for stabilize the conditions. This will
allow lower pulse duty factor and will reduce the average gap current.

3.4.2 Peak Current

The peak current is represented by IP and it is the maximum value of the current
passing through the electrodes for the given pulse. 810 ampere is the IP setting current
range available on the present WEDM which is applied in steps of 1 ampere. Increase in
23

the IP value will increase the pulse discharge energy which in turn can improve the
cutting rate further. For higher value of IP, gap conditions may become unstable with
improper combination of T
on
, T
off
, SV & SF settings.

3.4.3 Wire Feed

Wire feed is the rate at which the wire-electrode travels along the wire guide path
and is fed continuously for sparking. 810 m/min is the wire feed range available on the
present WEDM in steps of 1m/min. It is always desirable to set the wire feed to
maximum. This will result in less wire breakage, better machining stability and slightly
more cutting speed.

3.4.4 Wire Tension

Wire tension determines how much the wire is to be stretched between upper and
lower wire guides. This is a gram-equivalent load with which the continuously fed wire is
kept under tension so that it remains straight between the wire guides. More the thickness
of job more is the tension required. Inaccuracies in the job will occur as well as wire
breakage if the parameter in improper setting of tension. The wire tension range available
on the machine is 8-10 units in steps of 1.

3.5 Design of experiment

In general usage, design of experiments (DOE) or experimental design is the
design of any information-gathering exercises where variation is present, whether under
the full control of the researcher or not. However, in statistics, these terms are usually
used for controlled experiments. Formal planned experimentation is often used in
evaluating physical objects, structures, components, materials and chemical formulations.
Other types of study, and their design, are discussed in the articles on natural
experiments, quasi-experiments, opinion polls and statistical surveys.
24

In the design of experiments, the researcher is often interested in the effect of
some process or intervention on some objects, which may be people, parts of people,
groups of people, animals, plants, etc. Design of experiments is thus a discipline that has
very broad application across all the natural and social sciences and engineering.
























25

Table 3.2: Design of Experiment
Experiment No Pulse-Off Time Peak Current Wire Tension Feed Rate
1 1 8 8 8
2 1 8 8 8
3 1 8 8 8
4 1 9 9 9
5 1 9 9 9
6 1 9 9 9
7 1 10 10 10
8 1 10 10 10
9 1 10 10 10
10 3 8 9 10
11 3 8 9 10
12 3 8 9 10
13 3 9 10 8
14 3 9 10 8
15 3 9 10 8
16 3 10 8 9
17 3 10 8 9
18 3 10 8 9
19 5 8 10 9
20 5 8 10 9
21 5 8 10 9
22 5 9 8 10
23 5 9 8 10
24 5 9 8 10
25 5 10 9 8
26 5 10 9 8
27 5 10 9 8

26

3.6 Specimen preparation
3.6.1 Procedure

The experiments were accomplished on a Mitsubishi FX series WEDM machine.
Following steps were followed in the cutting operation:
1. The wire was made vertical with the help of verticality block.
2. The work piece was mounted and clamped on the work table.
3. A reference point on the work piece was set for setting work co-ordinate system
(WCS). The programming was done with the reference to the WCS. The reference point
was defined by the ground edges of the work piece.
4. The program was made for cutting operation of the work piece and a profile of 10 mm
x 10 mm square was cut.

3.7 Constant machining parameters use in the cutting process

Table 3.3: The constant machining parameters uses in the cutting process in this
study
No Parameter Symbol Value Units
1 Pulse-on time T
on
1 sec
2 Flushing pressure of dielectric fluid WP 5 kg/cm
2

3 Spark gap voltage setting SV 8 Volts
4 Servo feed setting SF 500 mm/min

3.7.1 Spark Gap Set Voltage

The spark gap set voltage is a reference voltage for the actual gap between the
work piece and the wire used for cutting. The SV voltage range accessible on the
machinery used in this study is 00 - 99 volt and is applied in steps of 1volt.
27

3.7.2 Pulse Peak Voltage

Pulse peak voltage setting is for selection of open gap voltage. Increase in the VP
value will increase the pulse discharge energy which in turn can improve the cutting rate.
The pulse peak voltage setting range available on the machine is either 1 or 2 .Normally
it is selected at value 2.

3.7.3 Flushing Pressure

Flushing Pressure is for selection of flushing input pressure of the dielectric. The
flushing pressure range on this machine is either 1 (High) or 0 (low). High input pressure
of water dielectric is necessary for cutting with higher values of pulse power and also
while cutting the work piece of more thickness. Low input pressure is used for thin work
piece and in trim cuts.

3.7.4 Servo Feed

Servo feed setting decides the servo speed; the servo speed, at the set value of SF,
can vary in proportion with the gap voltage (normal feed mode) or can be held constant
while machining (with constant feed mode).
The ranges of process parameters for the experiments were decided on the basis of
literature survey and the pilot experiments conducted using one factor at a time approach
(OFAT). Results of the pilot experiments are given in subsequent sections.

3.7.5 Pulse On-Time

Pulse on time is defined as the time during which the machining is performed.
The machining process becomes faster after increasing the pulse on time. If the pulse on
28

time increasing, the material removal rate also increasing. Because of that, it will produce
the poor surface finish on the specimen.

3.8 Measurement test and analysis Methodology
3.8.1 Cutting Rate (CR)

For WEDM, cutting rate is a desirable characteristic and it should be as high as
possible to give least machine cycle time leading to increased productivity. In the present
study cutting rate is a measure of job cutting which is digitally displayed on the screen of
the machine and is given quantitatively in mm/min.

3.8.2 Material Removal Rate (MRR)

Weight before machining, minus to weight after machining, divide to the time
taken for machining.
MRR =
( ) ( )

The quality of characteristic for MRR is the higher the better.

3.8.3 Surface Roughness (Ra)

Since irregularities in the surface may form nucleation sites for cracks or
corrosion, roughness is often a good predictor of the performance of a mechanical
component. Roughness is a measure of the texture of a surface. It is measured by the
vertical deviations of a real surface from its ideal form. If these deviations are large, the
surface is rough otherwise if these deviation if small, the surface is smooth. Roughness is
typically considered to be the higher frequency, shorter wavelength component of a
measured surface.

29

3.9 Taguchi method

Taguchis comprehensive system of quality engineering is one of the greatest
engineering achievements of the 20th century. This method focuses on the effective
application of engineering strategies. It includes both, shop-floor quality engineering and
upstream. Upstream methods competently use small-scale experiments to decrease
remain cost-effective and variability and robust designs for market place and large-scale
production. Shop-floor techniques provide real time methods for monitoring, maintaining
quality in production and cost-based. The farther upstream a quality method is applied,
the greater leverages it produces on the improvement, and the more it decreases the cost
and time.

3.9.1 Full Factorial

The full factorial design is the technique of defining and investigating all
conditions in an experiment while the fractional factorial design investigates only a
fraction of all the combinations. The Taguchi method has been proposed by simplifying
and standardizing the fractional factorial design. Taguchi method employs a special
design of orthogonal array to investigate the effects of the entire machining parameters
through small number of experiments. The methodology involves identification of
controllable and uncontrollable parameters and the establishment of a series of
experiments to find out the optimum combination of parameter which has greatest
influence on the performance and the least variation from the target of the design.

3.9.2 Signal-to-noise ratio

The S/N ratio, as stated earlier, is a concurrent statistic. A concurrent statistic is
able to look at two characteristics of a distribution and roll these characteristics into a
30

single number or figure of merit. The S/N ratio combines the variance around this mean
and mean level of the quality characteristic into a single metric.
A high value of S/N implies that signal is much higher than the random effects of
noise factors. Process operation consistent with highest S/N always yields optimum
quality with minimum variation.

3.9.3 Orthogonal array

In selecting an appropriate OA, the pre-requisites are:
Selection of process parameters and/or interactions to be evaluated
Selection of number of levels for the selected parameters

The determination of parameters to investigate depends upon the product or
process performance characteristics or responses of interest. Several methods are
suggested by Taguchi for determining which parameters to include in an experiment.
a) Brainstorming
b) Flow charting
c) Cause-Effect diagrams
The total Degrees of Freedom (DOF) of an experiment is a direct function of total
number of trials. If the number of levels of a parameter increases, the DOF of the
parameter also increases because the DOF of a parameter is the number of levels minus
one. Thus, increasing the number of levels for a parameter increases the total degrees of
freedom in the experiment which in turn increases the total number of trials. Thus, two
levels for each parameter are recommended to minimize the size of the experiment [11].
If curved or higher order polynomial relationship between the parameters under study and
the response is expected, at least three levels for each parameter should be considered.
31

3.9.4 Analysis of Variance (ANOVA)

For the analysis of variance, the total sum of squares may be divided into four parts[:
The contribution due to the first order terms
The contribution due to the second order terms
A Lack of fit component which measures the deviations of the response
from the fitted surface
Experimental error which is obtained from the centre points
3.10 Experimental and measurement equipment
3.10.1 Mitsubishi FX series WEDM flushing type


Display screen
Work tank
Work head
Power on/off
Keyboard
32

3.10.2 Portable surface roughness tester


Display screen
Parameter control
Power on/off
Probe
33

3.10.4 Work piece weighing machine



Power on/off
Display screen
34





CHAPTER 4



EXPERIMENTAL RESULTS AND ANALYSIS: TAGUCHI METHOD

4.1 Introduction

The present chapter gives the application of the Taguchi Method. The design of
experiments was selected and the experiments were conducted to investigate the effect of
process parameters on the output parameters e.g. surface roughness, material removal
rate. The experimental results are discussed subsequently in this chapter. The selected
process variables were varied up to three levels and L27 orthogonal array was adopted to
design the experiments. The Taguchi Method was selected to design the experimental
design and to analyze the data through signal-to-noise(S/N) ratio.



35

4.2 Data Collection
4.2.1 Surface Roughness

Table above show the data collection of surface roughness data. The surface
roughness data collection recorded by using portable surface roughness tester. For each
experiment, three reading for surface roughness recorded which is at the starting point,
middle point and end point of the specimen. The graph of surface roughness versus no. of
experiment was plotted. The maximum surface roughness was at the experiment number
15 which is in the condition of lowest feed rate while the minimum surface roughness
was at the experiment number 19 which is in condition highest pulse-off-time and lowest
peak current.













36

Table 4.1: Surface Roughness by Portable Surface Roughness Tester
Experiment No
Start
(m)
Middle
(m)
End
(m) Average Max Min
Max
Error
Min
Error
1 4.57 2.43 2.72 3.24 4.57 2.43 1.33 0.81
2 4.35 2.51 2.90 3.43 4.35 2.51 0.92 0.92
3 4.70 4.75 3.10 4.75 4.75 4.75 0.00 0.00
4 4.67 3.26 2.80 3.97 4.67 3.26 0.71 0.71
5 3.54 3.38 3.10 3.46 3.54 3.38 0.08 0.08
6 3.19 3.29 3.40 3.24 3.29 3.19 0.05 0.05
7 3.47 3.24 3.52 3.41 3.52 3.24 0.11 0.17
8 3.13 3.42 3.61 3.39 3.61 3.13 0.22 0.26
9 3.01 3.22 3.31 3.18 3.31 3.01 0.13 0.17
10 3.16 2.96 3.09 3.07 3.16 2.96 0.09 0.11
11 2.86 4.84 3.06 3.59 4.84 2.86 1.25 0.73
12 5.28 4.84 2.92 4.35 5.28 2.92 0.93 1.43
13 4.88 4.81 3.19 4.29 4.88 3.19 0.59 1.10
14 5.00 3.48 3.08 3.28 3.48 3.08 0.20 0.20
15 6.45 6.13 2.99 5.19 6.45 2.99 1.26 2.20
16 5.62 3.02 2.88 3.84 5.62 2.88 1.78 0.96
17 5.85 3.22 3.28 4.12 5.85 3.22 1.73 0.90
18 3.24 3.28 2.88 3.13 3.28 2.88 0.15 0.25
19 2.34 2.80 2.73 2.54 2.73 2.34 0.20 0.20
20 2.78 2.85 2.46 2.70 2.85 2.46 0.15 0.24
21 2.66 2.93 2.91 2.83 2.93 2.66 0.10 0.17
22 3.03 2.47 3.09 2.86 3.09 2.47 0.23 0.39
23 2.83 2.42 2.99 2.75 2.99 2.42 0.24 0.33
24 2.92 2.97 2.50 2.95 2.97 2.92 0.02 0.03
25 3.37 2.99 3.13 3.16 3.37 2.99 0.21 0.17
26 2.63 3.15 2.85 2.88 3.15 2.63 0.27 0.25
27 3.12 2.95 2.71 2.93 3.12 2.71 0.19 0.22
37

The surface roughnesses were taken at three points to get the accurate data surface
roughness of the specimen. The considered points are at the start point, middle point and
at the end point of the specimen as shown in figure 4.1. After completed the surface
roughness data taking process, the averages were calculated and the maximum and
minimum error are obtained to plot the graph 4.1.
Figure 4.1: Point of The Specimens Surface Roughness Taken





end
middle
start
38

Table 4.2: Feed Rate Cutting
Experiment No

Feed Rate Cutting (mm/min)
Start End Average
1 7.105 13.482 10.294
2 7.409 13.274 10.342
3 7.433 11.559 9.496
4 8.851 7.230 8.041
5 8.829 7.261 8.045
6 8.913 13.724 11.319
7 8.910 13.772 11.341
8 10.369 13.740 12.055
9 9.115 8.835 8.975
10 8.028 13.772 10.900
11 7.797 13.796 10.797
12 6.728 13.700 10.214
13 9.501 7.704 8.603
14 7.888 9.888 8.888
15 9.041 13.784 11.413
16 9.343 7.767 8.555
17 10.642 13.712 12.177
18 10.099 9.456 9.778
19 8.347 13.736 11.042
20 7.005 6.507 6.756
21 8.554 10.414 9.484
22 9.855 7.206 8.531
23 9.338 7.108 8.223
24 9.612 13.712 11.662
25 10.740 9.146 9.943
26 9.962 9.383 9.673
27 10.433 9.268 9.851
39

4.2.3 Specimen Weight and the Time Taken

While cutting the specimen, each of the specimen and the time taken to cut the
specimen was collected. The time taken was depending on the peak current which is the
time taken to cut the specimen decrease while the peak current increase and the time
taken to cut the specimen increase while the peak current increase.

















40

Table 4.3: Specimen Weight and the Time Taken
Experiment No
Specimen
Weight (g)
Time
Taken (s)
1 6.353 512
2 6.385 509
3 6.353 511
4 6.376 422
5 6.377 421
6 6.366 421
7 6.356 367
8 6.345 375
9 6.327 432
10 6.327 471
11 6.310 469
12 6.227 468
13 6.240 379
14 6.248 375
15 6.233 378
16 6.244 390
17 6.220 404
18 6.222 388
19 6.212 470
20 6.207 468
21 6.190 471
22 6.174 424
23 6.166 423
24 6.162 423
25 6.140 393
26 6.124 328
27 6.125 326
41


4.2.4 Surface Roughness, Material Removal Rate and Cutting Rate

The WEDM experiments were conducted, with the process parameter levels set as
given in Table 4.4, to study the effect of process parameters over the output parameters.
Experiments were conducted according to the test conditions specified by L27 orthogonal
array design. Experimental results are also given in Table 4.4 for cutting rate, surface
roughness, and material removal rate. Altogether 27 experiments were conducted using
Taguchi Method.
From the data collection, the significant factor that affecting the material removal
rate is peak current which is the material removal rate increasing by increasing the peak
current. Peak current also was the significant factor that affecting the time taken to cut the
specimen. For the surface roughness, the significant factor that affecting the surface
roughness was the wire tension which is the surface roughness increasing by decreasing
the wire tension.










42

Table 4.4: The Surface Roughness, Material Removal Rate and Cutting Rate
Experiment
No
Pulse-Off
Time
Peak
Current
Wire
Tension
Feed
Rate
SR
(m)
MRR
(g/s)
CR
(mm/min)
1 1 8 8 8 3.240 0.012 10.294
2 1 8 8 8 3.430 0.013 10.342
3 1 8 8 8 4.750 0.012 9.496
4 1 9 9 9 3.965 0.015 8.041
5 1 9 9 9 3.460 0.015 8.045
6 1 9 9 9 3.240 0.015 11.319
7 1 10 10 10 3.410 0.017 11.341
8 1 10 10 10 3.387 0.017 12.055
9 1 10 10 10 3.180 0.015 8.975
10 3 8 9 10 3.070 0.013 10.900
11 3 8 9 10 3.587 0.013 10.797
12 3 8 9 10 4.347 0.013 10.214
13 3 9 10 8 4.293 0.016 8.603
14 3 9 10 8 3.280 0.017 8.888
15 3 9 10 8 5.190 0.016 11.413
16 3 10 8 9 3.840 0.016 8.555
17 3 10 8 9 4.117 0.015 12.177
18 3 10 8 9 3.133 0.016 9.778
19 5 8 10 9 2.535 0.013 11.042
20 5 8 10 9 2.697 0.013 6.756
21 5 8 10 9 2.833 0.013 9.484
22 5 9 8 10 2.863 0.015 8.531
23 5 9 8 10 2.747 0.015 8.223
24 5 9 8 10 2.945 0.015 11.662
25 5 10 9 8 3.163 0.016 9.943
26 5 10 9 8 2.877 0.019 9.673
27 5 10 9 8 2.927 0.019 9.851
43



Graph 4.1: Graph Surface Roughness versus Number of Experiment
Graph 4.1 shows that the surface roughness of the entire specimen was uneven. In
overall, the specimen that has the highest surface roughness is specimen 15 which is had
been cut at the highest wire tension which is 10 and lowest wire speed which is 8 at
5.19m. Otherwise, the specimen that has the lowest surface roughness is specimen 19
which is had been cut at the lowest peak current and highest wire tension. In this case the
significant parameters are peak current and wire speed.



0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
S
u
r
f
a
c
e

r
o
u
g
h
n
e
s
s

No of Experiments
Surface Roughness
44


Graph 4.3 MRR versus No of Experiment
Graph 4.3 shows that the material removal rate of the entire specimen was
uneven. In overall, the specimen that has the highest surface roughness is specimen 27
which is had been cut at the highest pulse-off-time which is 5 and highest peak current
which is 10 at 0.188 g/s. Otherwise, the specimen that has the lowest material removal
rate is specimen 1 which is had been cut at the lowest pulse-off-time, peak current, wire
tension and wire feed at 0.0124. In this case the significant parameters are pulse-off-time,
peak current and wire speed.







0.0000
0.0020
0.0040
0.0060
0.0080
0.0100
0.0120
0.0140
0.0160
0.0180
0.0200
1 2 3 4 5 6 7 8 9 101112131415161718192021222324252627
M
R
R

No of Experiment
MRR
MRR
45

4.2.5 Signal to Noise Ratio

Table 4.5.: Signal-to-Noise Ratio for Surface Roughness
Level Pulse-Off Time Peak Current Wire Tension Feed Rate
1 -11.0779 -10.5728341 -10.75328343 -11.3274
2 -11.83559816 -10.9581219 -10.64734816 -10.3524
3 -9.073962523 -10.4565381 -10.58686258 -10.3076

The signal-to-noise-ratio for surface roughness was lowest at the first level of
pulse-off-time, wire tension and feed rate. This shows that pulse-off-time, wire tension
and feed rate is the significant parameters to the surface roughness.


Figure 4.1: Effects of Process Parameters on Surface Roughness (S/N Data)


46

Table 4.6: Signal-to-Noise Ratio for Material Removal Rate
Level Pulse-Off Time Peak Current Wire Tension Feed Rate
1 -36.77534892 -37.7108079 -24.70417734 -36.2865
2 -36.37133627 -36.2559502 -36.33523968 -36.387
3 -36.48528973 -35.6652168 -36.3486579 -36.6744

The signal-to-noise-ratio for material removal rate was highest at the third level of
pulse-off-time and peak current. This shows that pulse-off-time and peak current is the
significant parameters to the material removal rate.

Figure 4.3: Effects of Process Parameters on Material Removal Rate (S/N Data)




47

Table 4.7: Signal-to-Noise Ratio for Cutting Rate
Level Pulse-Off Time Peak Current Wire Tension Cutting Rate
1 18.89938701 22.71033485 18.42785025 26.49133
2 19.9677491 14.5027131 26.64473055 13.65512
3 21.15596541 22.81005358 14.95052073 19.87665

In this study, the cutting rate was not considered due to the problem while the data
collection process.

Figure 4.5: Effects of Process Parameters on Cutting Rate (S/N Data)





48

4.2.6 Main Effects Plot for Means (Raw Data)

Figure 4.2: Effects of Process Parameters on Surface Roughness (Raw Data)

Figure 4.4: Effects of Process Parameters on Material Removal Rate (Raw Data)

49


Figure 4.6: Effects of Process Parameters on Cutting Rate (Raw Data)








50





CHAPTER 5



DISCUSSION

1. In this investigation, the best parametric combination was obtained. The
conclusion done by considering the set of parameters that produce the lowest
signal-to-noise ratio for surface finish and the higher signal-to-noise ratio
material removal rate.
2. From this investigation, the set of parameters that has the minimum surface
finish is experiment number 15 which is have the reading of surface roughness
5.190 m.
3. The signal-to-noise-ratio for surface roughness was lowest at the first level of
pulse-off-time, wire tension and feed rate.
4. This shows that pulse-off-time, wire tension and feed rate is the significant
parameters to the surface roughness.
5. The higher material removal rate seen at the set of parameters no 26 and 27 with
the material removal rate 0.019 g/s.
6. The signal-to-noise-ratio for material removal rate was highest at the third level
of pulse-off-time and peak current.
51

7. This shows that pulse-off-time and peak current is the significant parameters to
the material removal rate.
8. The cutting rate was not considered due to the problem while the data collection
process which certain data taken while the wire electrode had touched the
material and the others data taken while the wire electrode do not touch the
material. So that, the result is invalid.
















52





CHAPTER 6



CONCLUSION

6.1 Introduction

In the previous chapters, the effects of process variables on response
characteristics (cutting rate, surface roughness, material removal rate) of the wire
electric discharge machining (WEDM) process have been discussed. An optimal set of
process variables that yields the optimum quality features to machined parts produced by
WEDM process has also been obtained. The important conclusions from the present
research work are summarized in this chapter.

6.2 Conclusions

For the conclusion, the best parameter to obtain the various shapes of structural
components the wire-cut EDM process and improving the machining efficiency which is
produce the product that have lowest surface roughness is the parameters with the
minimum feed rate, maximum pulse-off-time and maximum peak current.
53

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54

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