Machining Parameter Optimization of Wire Cut EDM Machine Using Taguchi's Design of Experiment (DOE)

Wire cut EDM process is a complicated machining process, which is controlled by more than ten machining parameters. The situation is really tough to find the different parametric combinations for variety of machining situations. The design of experiments coined by Dr. Genichi Taguchi is used to find the parametric combinations. The objective of the paper is to analyze and find optimum parameters for the minimum surface roughness along with cutting speed of typical die steel plate. The workpiece selected for carrying the experiment is 30 mm thick steel OHNS plate. The surface roughness is measured using a surface roughness-measuring instrument. The cutting speed is noted directly form the LED display in the machine. The experiments are planned and conducted according to the DOE process. The ANOVA analysis is done to analyze the Taguchi's design of experiments problems. The optimum conditions for the minimum surface roughness directly vary with the optimum conditions for the cutting speed.