Optimization of process parameters in Wire-EDM: By D3 tool steel using Taguchi Method

D3Tool steel is a high carbon, air hardened and high chromium tool steel. It possess high compressive strength and good dimensional stability. It is used in wide applications in industries like bushes, press tools, forming rolls, blanking dies, forming dies and punches. Wire EDM is a non conventional process of machining which is used for precision machining. It is a micro machining process used for manufacturing complex shapes with extremely close tolerances. The performance of Wire EDM is affected by various parameters. In this paper we attempt to optimize the machining parameters for achieving highest MRR (Material Removal Rate). For studying the performance characteristics we make use of L9 Orthogonal array, S/N ratio (signal to noise ratio). The process parameters considered for investigation are pulse on time, pulse off time, servo feed. Material removal rate was calculated using formulas. After the experimentation Taguchi Method is used to obtain the optimum levels. The experimental analysis resulted into combination of pulse on time, pulse off time and servo feed to achieve maximum MRR.