Investigation Effect of the Machining Parameters on the Material Removal Rate in the WEDM of AISI D3 Tool Steel

Tool steel, AISI D3, is widely used in tool and die making industries due to its high strength and toughness. In this article, an attempt has been made to investigate the effect of the machining parameters, such as pulse on time (T_on), pulse off time (T_off), gap voltage (v) and wire tension (WT) on the material removal rate (MRR) in the WEDM of AISI D3 tool steel, to improve the machining rate in manufacturing industries. The experiments were conducted using Taguchi's experimental design. An orthogonal array L₁₆ was used to conduct the experiments. The effect of the machining parameters on the material removal rate is evaluated. Experimental data are analyzed with the analysis of variance (ANOVA). A second order response surface model has been established between the machining parameters and the MRR, using response surface methodology. The experimental results indicate that the pulse off time (T_off) significantly affects the MRR, followed by pulse on time (T_on) and gap voltage (v). The predicted values are very close to the experimental values.