Optimization of Process Parameter of Wire Electrical Discharge Machine by Response Surface Methodology on Inconel-600

in the present paper, the study has been made to optimize the process parameters during machining of Inconnel-600 by wire electrical discharge machining (WEDM) using response surface methodology (RSM). Four input process parameters of WEDM (namely Peak Current (IP), Pulse-On time (TON), Pulse-Off time (TOFF) and Wire Feed rate (WF)) were chosen as variables to study the process performance in terms of Material Removal Rate (MRR). In the present work, the parametric optimization method using Taguchi’s robust design is proposed for wire-cut electric discharge machining of Inconel-600. This material is gained dominance, where high strength and/or hardness is required at elevated temperatures. So, experimentation has been done by using Taguchi’s Mixed L18 (2x3) orthogonal array. Each experiment was conducted under different conditions of pulse on time, pulse off time, peak current, and wire feed rate. The response of material removal rate is considered for improving the machining efficiency. Optimal combinations of parameters were obtained by this method. The analysis of variance (ANOVA) was carried out to study the effect of process parameters on process performance. In addition Response Surface Models have also been developed for response parameter. Keywords—WEDM, MRR, RSM, ANOVA, Taguchi L18 OA, Molybdenum wire.