Optimization of Material Removal Rate of WEDM Process on Mild Steel Using Molybdenum Wire

For any manufacturing process and, particularly, in process related to WEDM the correct selection of process parameters is one of the most important aspects to be taken into consideration. WEDM is capable of machining geometrically complex shapes or hard material components, such as composites, carbides, heat treated tool steels, super alloys, ceramics and heat resistant steels etc. These hard material components are widely used in die and mold making industries, aerospace, aeronautics and nuclear industries. This study discusses the influence of process parameters like current, Pulse on time, Pulse off Time and Voltage on the performance parameters such as material removal rate. The experiment has been conducted on Mild Steel work piece using brass wire, because Mild Steel has various industrial applications in manufacturing of frame of motorcycles, dies, automobile chassis, base of boilers and cook wares etc. The experimental layout is based on Taguchi L16 orthogonal array. Further, the analysis of variance [ANOVA] is used to analyze the results obtained from Taguchi method. The analysis of results obtained for material removal rate indicate that current and pulse on time has the highest impact on material removal rate. As the current and pulse on time increases, the material removal rate also increases. Pulse off time and voltage has no significant effect on material removal rate