DOI 10.

1007/s00170-004-2496-6
ORIGINAL ARTICLE
Int J Adv Manuf Technol (2006) 29: 105112
R. Ramakrishnan L. Karunamoorthy
Multi response optimization of wire EDM operations
using robust design of experiments
Received: 15 September 2004 / Accepted: 22 November 2004 / Published online: 6
July 2005
Springer-Verlag London Limited 2005
Abstract In this present study a multi response optimization method using
Taguchis robust design approach is proposed for wire electrical discharge
machining (WEDM) operations. Experimentation was planned as per Taguchis
L16 orthogonal array.
Each experiment has been performed under different cutting conditions of pulse on
time, wire tension, delay time, wire feed, speed, and ignition current intensity.
Three responses namely material removal rate, surface roughness, and wire wear
ratio have been considered for each experiment. The machining parameters are
optimized with the multi response characteristics of the material removal rate,
surface roughness, and wire wear ratio. Multi response S/N (MRSN) ratio was
applied to measure the performance characteristics deviating from the actual value.
Analysis of variance (ANOVA) is employed to identify the level of importance of
the machining parameters on the multiple performance characteristics considered.
Finally experimental confirmation was carried out to identify the effectiveness of
this proposed method. A good improvement was obtained.
Keywords ANOVA MRR MRSN Surface roughness
WEDM WWR
1 Introduction

The wire electro discharge machining (WEDM) process contributes a predominant

role in some manufacturing sectors recently; since this process has the capacity to
cut complex and intricate shapes of components in all electrically conductive
materials with better precision and accuracy. In the WEDM process, there is no
relative contact between the tool and work material, therefore the work material
hardness is not a limiting factor for machining materials by this process. In this
operation the material removal occurs from any electrically conductive material
by the initiation of rapid and repetitive spark discharges between the gap of the
work and tool electrode connected in an electrical circuit [13] and the liquid
dielectric medium is continuously supplied to deliver the eroded particles and to
provide the cooling effect. A small diameter wire ranging from 0.05 to 0.25 mm is
applied as the tool electrode [4]. The wire is continuously supplied from the
supply spool through the work-piece, which is clamped on the table by the wire
traction rollers. A gap of 0.025 to 0.05 mm is maintained constantly between the
wire and work-piece [5]. Deionized water of 15 micro semen/cm is applied as the
dielectric fluid [3]. A collection tank that is located at the bottom is used to collect
the used wire and then discard it. The wires once used cannot be reused again
due to the variation in dimensional accuracy [6]. The dielectric fluid is
continuously flashed through the gap along the wire, to the sparking area to
remove the byproducts formed during the erosion [7]. Brass, aluminum and zinc
coated brass or copper wires are widely applied as the tool electrode. Nowadays
WEDM is an important machine tool to produce complex and intricate shapes of
components in areas such as tool and die making industries, automobile, aerospace,
nuclear, computer, and electronics industries.
2 Literature review
Since WEDM is an essential operation in several manufacturing processes in some
industries, which need variety, precision and accuracy are of great important. In

order to improve the performance namely the surface roughness, cutting speed,
dimensional accuracy, and material removal rate of the WEDM process several
researchers have attempted previously. However, the full potential utilization of
this process is not completely solved because of its complex and stochastic
nature and the increased number of variables involved in this operation [2, 6].
The various technological and NC aspects of the WEDM process were analyzed
by [8]. Kinoshita et al. [9] pointed out that the ratio between the equilibrium
clearance and the amplitude of wire vibration is the most appropriate value to
judge the short circuit gap. A number of authors have performed research related
to wire rupture problems. To avoid short sparks which causes the wire to rupture,
Tanimura et al. [10] developed a short circuit detecting system, which is
performed by adjusting the chock inductance of the pulse generator. They
reported that the unusual high rate of short circuit pulses during a period of 30 ms
or more proceeds wire rupture. Kinoshita et al. [11] analyzed the various types of
wire breaking. To prevent the wire breaking they developed a control system by
means of monitoring the pulse frequency. Once a sudden rise of pulse frequency
was detected, the pulse generator and servo system was turned off instantaneously
to prevent the wire rupture from breaking. However, the machining efficiency was
much reduced by such control strategy and the system was good if the work-piece
thickness is restricted to 20 mm. Scott et al. [6] constructed a mathematical model
to predict the material removal rate and surface finish when machining D2 tool
steel material at different machining conditions. They found that there is no
single combination of levels of the different factors that can be optimal under all
circumstances. To find the optimal machining parameters the non-dominated point
approach was applied, using explicit enumeration of all possible combinations and
the dynamic programming method. Dauw et al. [7] developed a mathematical
model to analyze the wire deflection during machining. The deviation of the wire

position relative to the programmed wire path position was continuously measured
and corrections were made during machining of complex shapes, arc, and contours.
In this study, substantial gain of machining time and improvement in corners
accuracy was obtained. Tarng et al. [12] formulated a neural network model and
simulated annealing algorithm in order to predict and optimize the surface
roughness and cutting velocity of the WEDM process when machining SUS304
stainless steel materials. Spedding et al. [2] attempted to model the WEDM
process through the response surface methodology and artificial neural
networks and found that the model accuracy of both was better. The same
authors [5] attempted further to optimize the surface roughness, surface
waviness, and speed of the artificial neural networks predicted values using a
constrained optimization model. Huse et al. [13] developed a model to estimate
the MRR in corner cutting of the WEDM by considering wire deflection in terms
of discharge angle. Lin [14] et al. proposed a control strategy based on Fuzzy
logic to improve the machining accuracy at corner parts of the WEDM process.
Jun Qu et al. [15] derived a mathematical model for the material removal rate of
a cylindrical wire EDM process. The same authors [16] investigated through a
mathematical model the surface integrity and roundness of cylindrical WEDM
parts using brass and carbide work material. They found through the model a
good estimate of the surface finish and roundness of cylindrical WEDM parts.
Gokler et al. [17] investigated under various experimental conditions the surface
roughness achievable for 1040, 2379, and 2738 steel materials and the relative
machining parameters for the WEDM process. Puri et al. [18] investigated the
variation of geometrical inaccuracy caused due to wire lag with various machine
control parameters. In order to predict the performance characteristics of the
WEDM process, Ramakrishnan et al. [19] developed a mathematical model
using the response surface methodology. A good amount of research has already

been done in the area of WEDM technology. To the best of the knowledge of the
authors of this work, there is not found any published paper for optimizing
multiple performance characteristics of the WEDM process using the Taguchi
method. Keeping this consideration in view, this paper describes optimization of
multiple performance characteristics using the robust parametric design approach,
for achieving a better material removal rate, surface finish, and wire wear ratio.
3 Methodology
Taguchis robust design is a simple, systematic and more efficient method to
determine optimum or near optimum settings of design parameters [20]. Many
researchers have attempted to analyze and optimize a single performance
characteristic of a manufacturing process using Taguchi methodology [5, 18, 20,
21]. However, optimization of multiple performance characteristics was rarely
discussed in literature [22]
Conclusions:
This paper described the multi objective optimization of the WEDM process
using parametric design of Taguchi methodology.
It was observed that the Taguchis parameter design is a simple, systematic,
reliable, and more efficient tool for optimization of the machining parameters.
The effect of various machining parameter such as pulse on time, wire tension,
delay time, wire feed speed, and ignition current intensity has been studied
though machining of heat-treated tool steel. It was identified that the pulse on
time and ignition current intensity has influenced more than the other
parameters considered in this study. Moreover the multiple performance
characteristics such as material removal rate, surface roughness, and wire wear
ratio for the WEDM process can be improved concurrently. The validity of the
developed optimization tool was tested and provides a consistent result.
Therefore a very beneficial multi objective optimization tool for manufacturing
system especially for WEDM operations has been proposed in this paper. From

the present analysis it is evident that the optimal parametric combination will be
very beneficial to the manufacturing communities who are working in the
WEDM process. Further research might attempt to consider the other
performance criteria, such as surface waviness, form accuracy, and surface
flatness as output parameters.
The technique presented in this study might also be tried for the other non-traditional
machining processes such as electro chemical machining, electron beam machining, laser
beam machining, and water jet machining operations for effective utilization of such machine
tools. This technique can also be applied for the various conventional machining operations to
improve the performance
characteristics simultaneously.

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