Modeling & Analysis of performance characteristics of Wire EDM of SS304

Wire electrical discharge machining (WEDM)allowed success in the production of newer materials, especiallyfor the aerospace and medical industries. Using WEDMtechnology, complicated cuts can be made throughdifficult-to-machine electrically conductive components. Thehigh degree of the obtainable accuracy and the fine surfacequality make WEDM valuable. WEDM is so complex in naturethat the selection of appropriate input parameters is not possibleby the trial-and-error method. The selection of machiningparameters in any machining process significantly affectsproduction rate, product quality and production cost of afinished component. WEDM process involves a large number ofvariables that affect its performance. However, based on theliterature survey and the pilot experiments, five processvariables, viz., pulse-on time, pulse-off time, wire tension, andwater pressure are taken into consideration for the research. Inthe present work Response Surface Methodology (RSM) is usedto develop the quantitative relationships between the input andthe output responses for the experimental data collected as perthe DOE. Also the effects of the input process parameters overthe MRR and Ra were plotted and studied. Later the developedmodels can be utilized for optimization.