3.1 the material removal rate, surface roughness used in

3.1   STATEMENT OF THE PROBLEM  

The literature
review shows that many people have worked on the Wire Electrical Discharge
Machining. Many researchers have studied the various responses like material
removal rate, surface finish, etc. Their values and nature of the responses
i.e. depends upon the range factor and selection of the various input
parameters i.e. turn on time, surface voltage, turn on time and wire feed time
etc. Few researchers investigated on different types of tools and other
parameters depending upon the need of material to be machined and their effects
have been studied. Various types of tools have been used for machining of
different materials. Lots of studies have been reported optimizing the Wire
Electrical Discharge Machining using the optimization techniques. Some of the
investigators worked on the effect of various machining parameters on material
removal rate and other compositional properties. They have only discussed the
effect of two few elements on the material removal rate. My research is to find
out the effects of various parameters on the material removal rate, surface
roughness used in the wire electrical discharge machining.

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·        
The present work “Experimental
Investigation and Optimization of Process Parameters in Wire Electrical
Discharge Machining of M6 HSS using Taguchi Optimization Technique” has
been undertaken keeping into consideration the following problems:

·        
How the various control factors will
affect the response characteristics (metal Removal rate, surface roughness) of
WEDM?

·        
How to find out the significant and non-significant
control factors and modeled the process according to significant control
factors?

3.2  
Objectives of the Present Investigation

·        
To investigate the working ranges of the
WEDM control factors using one  factor at
a time approach (OFTA).

·        
To 
investigate the effects of the control factors like pulse on time, pulse
off time, spark gap voltage, peak current and wire tension on the response
variables like metal removal rate and surface roughness in WEDM process.

·        
To optimized the
response variables using Minitab software.

·        
To validate the results by conducting
confirmation experiments.

·        
To produce a regression equation.

3.3    PROBLEM ENCOUNTERED DURING MACHINING OF M6
HSS

It is very difficult to
produce complicated shape by machining of M6 HSS with conventional machining
process. The Non-Conventional machining method has been selected to overcome
this problem i.e. WEDM process. Following are the problems encountered while
machining of M6 HSS.

·        
Rapid tool failure

·        
Requirement of larger current values

·        
Irregular and fluctuating metal removal
rate

·        
Very poor surface finish

·        
Difficult
to cut a complicated profile