Optimization of Process Parameters of Wire Electric Discharge Machining Process for Machining AISI A2 Tool Steel

Abstract

In this investigation, AISI A2 tool steel is considered as the workpiece material, which is typically used to manufacture blanking tools, punches die etc., due to its good toughness and wear resistance. In this work, the effect of controlling parameters of the Wire Electric Discharge Machining (WEDM) process is investigated. Molybdenum tool electrodes of 0.18mm diameter and de-ionized water dielectric medium are utilized. Peak current, on-time, off-time and voltage are considered as the controlling parameters. Surface roughness average and material erosion rate are considered as the response parameters. The type of design of experiments considered for this work is Taguchi’s L27 orthogonal array. Analysis of variance indicates the percentage contribution of each machining parameter on response parameters. The optimum combination of machining parameters yields a minimum surface roughness of 2.87 μm and the highest material removal rate obtained in this work is 774 mm3/hr.