Study on Effect of Wire EDM Process Parameters Using

MADM/MCDM Technique

A project report submitted in partial fulfilment of the requirement for

the award of the degree of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

BY

GOLIVI KUMAR (317126520082)

SAMALA VAMSI (318126520L13)

PURIYA SIVARAM (317126520110)

BORA SURESH REDDY (317126520069)

KUPPALA SAI VISWA TEJA (317126520093)

Under the esteemed guidance of

B.B. ASHOK KUMAR, M.Tech,(Ph.D)

Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

ANIL NEERUKONDA INSTITUTE OF TECHNOLOGY & SCIENCES (A)

(Affiliated to Andhra University, Accredited By NBA and NAAC with ‘A’ Grade )

SANGIVALASA, VISAKHAPATNAM (District) – 531162

 Abstract

Wire-electro discharge machining (WEDM) has become an important non-traditional

machining process, as it provides an effective solution for producing components made of
difficult-to-machine materials like titanium, zirconium, etc., and intricate shapes, which are not
possible by conventional machining methods. In the present work, an experimental investigation
has been done to evaluate the effect of Wire EDM parameters on the performance
characteristics. A medium carbon steel AISI 1040 has been taken as workpiece for the study
due to its high ultimate tensile strength and hardness. The Wire EDM parameters are planned
as per L18 0A for the experiments by taking brass wire as electrode and distilled water as
dielectric medium. The results of AHP with utility analysis revealed that wire tension is the
most influencing factor in achieving better multiple responses.
 CONTENTS

Page No.

CERTIFICATE ⅱ
CONTENTS ⅲ
LIST OF TABLES ⅳ
LIST OF FIGURES ⅴ

Chapter-1
INTRODUCTION 8
1.1. Non-Conventional Machining Process 8
1.2. Wire Cut Electric Discharge Machining 9
1.3. How Wire EDM Works 10
1.4. Steps Involved In Wire EDM Process 12

1.5. Process Parameters and Their Influence 14

1.6. Materials That WEDM Can Cut 21

1.7. Benefits of Wire EDM 23

Chapter-2

LITERATURE SURVEY 25

Chapter-3

METHODOLOGY 45

3.1. Design of Experiments (DOE) 45

3.2. Taguchi Optimization Method 46

3.3. Analytic Hierarchy process(AHP) 46

3.4. Taguchi-Utility Method 48

3.5 Proposed 49
Chapter-4

EXPERIMENTAL SETUP 50

4.1. WEDM Machine Details 51

4.2. Range of Process Parameters 52

4.3. Experimentation Procedure 55

Chapter-5

RESULTS AND DISCUSSIONS 57

5.1. Experimental Results 57

5.2. ANOVA Results 61

Chapter-6

CONCLUSION 63

Chapter-7

FUTURE SCOPE 64

REFERENCES 67
 LIST OF TABLES

Table no. Description page no.

1.1 Characteristics of Non-Conventional Machining 8

Process
2.1 Details of various EDM processes used by 28
researchers for different grades of tool steels
2.2 Main researches in optimizing process parameters 32
Of EDM machining
2.3 General effect of major operating parameters 44
on key performance measures.
4.1 Chemical Composition of AISI 1040 50
4.2 Mechanical Properties of AISI 1040 51
4.3 Process Parameters and Their Ranges 53
4.4 Process Parameters and Their Levels 53
4.5 L18 Orthogonal Array (OA) 54
5.1 Experimental Results 57
5.2 Pair Wise Comparison Matrix 58
5.3 Individual Utility Values of Responses 58
5.4 Overall Utility (U) and S/N Ratios of U 59
5.5 Mean Values of Overall Utility Values 60
5.6 ANOVA Results 61
 LIST OF FIGURES

Figure no. Description page no.

1.1 Wire Electrical Discharge Machining System 9

1.2 Close View of Cutting Zone in WEDM 10
1.3 Generation of Spark in WEDM 10
1.4 Path of Wire in WEDM 11
1.5 Power Generation in WEDM 12
1.6 Erosion of Material in WEDM 12
1.7 Spark Erosion during ON Time 13
1.8 Chip Removal by Filtration 13
1.9 Wire Cut Fluid Flow Nozzles 18
1.10 Full-Wire Finish Machining 19
1.11 Partial-Wire Finish Machining 20
1.12 Wire EDM Transport System 21
2.1 The processes of electric discharge machining (EDM) 27
and their process parameters and performance measures
2.2 Percentage of research related to EDM processes 43
4.1 AISI 1040 Steel 50
4.2 WEDM Setup 52
4.3 WEDM Brass Wire 55
4.4 Measurement of Surface Roughness 56
5.1 Main Effect Plot for Means of Overall Utility (U) 61
5.2 Residual Plots for Overall Utility 62
7.1 Future research areas in the EDM field 65
7.2 Classification of research directions 66
 CHAPTER 1
INTRODUCTION
In view of achieving higher production through consistent efforts by the manufacturing
engineer, the manufacturing scenario has drastically changed in the present day metal cutting
industry and focused towards an automated factory concept. Flexible Manufacturing System
(FMS), Computer Integrated Manufacturing Systems (CIMS), a wide application of industrial
robots, automated material handling and inspection systems has helped a lot in industrial
automation and better productivity. All such progress in machine tools and metal machining is
the outcome of the persistent effort, research work and logical thinking of scientists working in
the area of metal cutting to understand what is happening when a cutting tool is fed into the
work to cut the material.
1.1. Non-Conventional Machining Process
The conventional machining processes remove material by chip formation, abrasion or
micro chipping. There are situations where these processes are not satisfactory, economical, or
even impossible for the following reasons:

 The hardness and strength of the material is very high or the material is too brittle.
 The work piece is too flexible, slender, or delicate to withstand the cutting or grinding forces,
or the parts are difficult to fixture- that is, to clamp in work holding devices.
 The shape of the part is complex, including such features as internal and external profiles or
small-diameter holes.
 Surface finish and dimensional tolerance requirements are more rigorous than those obtained
by other processes.
 Temperature rise and residual stresses in the work piece are not desirable or acceptable.
These requirements led to the development of chemical, electrical, laser, and other
means of material removal, termed as un-conventional or non-traditional machining methods.
There are a number of un-conventional machining processes having different characteristics as
listed below in Table 1.1.

Table 1.1 Characteristics of Non-Conventional Machining Process

Process Characteristics

Chemical Machining Shallow removal on flat surfaces suitable for low production
runs

Electro Chemical Complex shapes with deep cavities can be machined with
Machining highest material removal rates

Electric Discharge Shaping and cutting complex parts made of hard materials,
Machining Some damage may occur due to spark erosion

Contour cutting of flat or curved surfaces; expensive

Wire EDM
equipment
 Cutting and hole making on thin materials.
Electron Beam
Machining Very small holes and slots can be made expensive equipment.
It requires vacuum.

Cutting and hole making on thin materials. Slots can be made;

Laser Beam Machining
expensive equipment. But, does not require vacuum as in EBM.

Cutting all types of metallic materials up to 25 mm thickness;

Water Jet Machining
no thermal damage; noisy

Cutting, slotting, deburring, etching of metallic and non-

Abrasive Jet Machining
metallic materials; tends to round off sharp edges.

Out of the above-mentioned processes, the present research is restricted to the Wire
Cut Electric Discharge Machining Process (WEDM).

1.2. Wire Cut Electric Discharge Machining

New materials created and/or demanded by space age technology sometimes cannot be
economically cut using conventional cutting tools. Special, super-hard materials, normally quite
expensive, are required. Synthetic diamonds or diamond compounds that are almost impossible
to grind are very expensive, but are cut effectively by WEDM. The process wastes very little
work piece material due to its small kerf size, coupled with the fact that the process can
accurately cut unusual shapes. In modern manufacturing industry, WEDM has been extensively
used to machine complicated shapes on advanced materials with high accuracy. WEDM is one
of the most extended non-conventional machining processes. It is widely used to machine dies
and moulds aimed at producing components for many industries. The main advantage of
WEDM is its capability for the production of high complexity shapes with a high degree of
accuracy, independently of mechanical properties of the material (especially, hardness,
brittleness and resistance). Wire EDM uses brass, tungsten, or copper as its material for the
electrode tool wire. Deionized water is used for the dielectric fluid. Almost like the standard
EDM, the wire is eroded and slowly fed. Although it is similar to standard EDM, higher currents
and lower rest times make this process much faster. Figure 1.1 shows the principle of WEDM
process and Figure 1.2 shows the close view of machining zone.

Figure 1.1 Wire Electrical Discharge Machining System

 Figure 1.2 Close View of Cutting Zone in WEDM
1.3. How Wire EDM Works
WEDM is a special form of electrical discharge machining wherein the electrode is a
continuously moving conductive wire. Material removal is effected as a result of spark erosion
as the wire electrode is fed (from a spool) through the work piece. Figure 1.3 shows schematic
view of generation of spark before the tool wire electrode starting the machining cycle.

Figure 1.3 Generation of Spark in WEDM

Rapid DC electrical pulses are generated between the wire electrode and the work
piece. Between the wire and the work piece is a shield of deionized water, called the dielectric
fluid. Pure water is an insulator, but tap water usually contains minerals that cause the water to
be too conductive for wire EDM. To control the water conductivity, the water goes through a
resin tank to remove much of its conductive elements; this is called de ionized water.
 When sufficient voltage is applied, the fluid ionizes. Then a controlled spark precisely
erodes a small section of the work piece, causing it to melt and vaporize. These electrical pulses
are repeated thousands of times per second. The pressurized cooling fluid, the dielectric, cools
the vaporized metal and forces the re solidified eroded particles from the gap. The dielectric
fluid goes through a filter which removes the suspended solids. Resin removes dissolved
particles; filters remove suspended particles. To maintain machine and part accuracy, the
dielectric fluid flows through a chiller to keep the liquid at a constant temperature.
The tool wire is usually made up of brass, copper or tungsten; zinc-or brass-coated and
multi-coated wires are also used. The wire diameter is typically about 0.30mm for roughing cuts
and 0.20mm for finishing cut. The wire should have sufficient tensile strength and fracture
toughness, as well as high electrical conductivity and capacity to flush away the debris produced
during cutting. The tool wire is generally used only once, as the wire gets deformed and loses
its tensile strength. The wire travels at a constant velocity in range of 0.15 to 9.0 m/min, and a
constant gap (kerf) is maintained during the cut. Figure 1.4 shows the path of wire generated by
CNC automated computer system.

Figure 1.4 Path of Wire in WEDM

A DC or AC servo system maintains a gap from .002 to .003" (.051 to .076 mm) between
the wire electrode and the work piece. The servo mechanism prevents the wire electrode from
shorting out against the work piece and advances the machine as it cuts the desired shape.
Because the wire never touches the work piece, wire EDM is a stress-free cutting operation.
1.4. Steps Involved In Wire EDM Process

Figure 1.5 Power Generation in WEDM

Power Supply Generates Volts and Amps: Deionized water surrounds the wire electrode
as the power supply generates volts and amps to produce the spark. Figure 1.5 shows how power
supply generates volts and amps.

Figure 1.6 Erosion of Material in WEDM

 During ON Time Controlled Spark Erodes Material: Figure: 1.6 shows how Sparks
precisely melt and vaporize the material.

Figure 1.7 Spark Erosion during ON Time

OFF Time Allows Fluid to Remove Eroded Particles: During the off cycle, the
pressurized dielectric fluid immediately cools the material and f1ushes the eroded particles as
shown in Figure 1.7.

Figure 1.8 Chip Removal by Filtration

Filter Removes Chips While the Cycle is Repeated: The eroded particles are removed
and separated by a filter system as shown in Figure 1.8.
1.5. Process Parameters and Their Influence
WEDM is complex in nature and controlled by large number of parameters. These
parameters have to be controlled for effective working of the cutting process. The parameters
may be grouped into input parameters and output parameters. Input parameters are those
variables which are required to run the cutting process. The output parameters are those which
are the outcome of the process and are observed on the finished work after cutting. Some of the
process parameters in WEDM process are:

Influence of Wire Material Characteristics

As WEDM uses a thin wire as a single electrode, it is not necessary to make different
shape of tool electrode to achieve the complex contours. However, to prevent the wire breaking,
it becomes critical to obtain a continuous machining process. There has been a lot of effort by
researchers over the years to improve the technology of the tool by overcoming the thermal
effects to prevent the tool wire from breaking during the process. The optimal selection of wire
properties would also determine its final performance.

Effect of Wire Tension

Within a considerable range, an increase in wire tension significantly increases the
cutting speed. A higher tension decreases the wire vibration amplitude and hence decreases the
cut width, so that the speed is higher for the same discharge energy. However, if the applied
tension exceeds the tensile strength of the wire, it leads to wire breakage.

Effect of Frequency
This is a measure of the number of time the current is turned on and off. During roughing
the ON time is increased significantly for high removal rates and there are fewer cycles per
Second hence a lower frequency setting. Finish cycles will many cycles per second hence a
larger frequency setting. Frequency should not be confused with the duty cycle as this is a
measure of efficiency.

Heat Affected Zone

The Wire EDM process is a thermal process and, therefore, some annealing of the work
piece can be expected in a zone just below the machined surface. In addition, not all of the work
piece material melted by the discharge is expelled into the dielectric. The remaining melted
material is quickly chilled, primarily by heat condition into the bulk of the work piece, resulting
in an exceedingly hard surface. Since, the annealing effect is most common when unstable
machining conditions exist, it can be reduced by choosing conditions that produce better
stability.

Thickness of the Work Piece

In the WEDM process, cutting speed decreases as the thickness of the work piece
increases. Normally, WEDM uses a transistor controlled capacitor circuit in which the cutting
speed is controlled by a capacitor value. When using a fixed capacitor to machine a thicker
work piece, the cutting speed is decreased.
Material of the Work Piece
Specific properties of the work piece material also influence the process. These
properties include how well the metal is polished, its magnetic condition, and how the metal
was removed from the heat treatment process when it was produced. One must also consider
expansion and contraction according to the temperature of the materiel. For material processed
by EDM or WEDM, the initial surface condition affects the results. A low melting point in the
material increases the MRR, and improper heat treatment of the metal results in distortion and
breakage of the mold.

Time ON

All the work is done during time ON. The spark gap is bridged, current is generated and the
work is accomplished. The longer the spark is sustained more is the material removal.
Consequently the resulting craters will be broader and deeper; therefore the surface finish will
be rougher. Obviously with shorter duration of sparks the surface finish will be better. With a
positively charged work piece the spark leaves the tool and strikes the work piece resulting in
the machining. Except during roughing all the sparks that leave the tool result in a microscopic
removal of particles of the surface. More sparks produce much more wear; hence this process
behaves quite opposite to normal processes in which the tool wears more during finishing than
roughing. Electrode material too plays a significant factor in tool wear.
Time OFF
While most of the machining takes place during time ON of the pulse, the time off during
which the pulse rests and the reionization of the die-electric takes place, can affect the speed of
the operation in a large way. More is the off time greater will be the machining time. But this is
an integral part of the EDM process and must exist. The time off also governs the stability of
the process. An insufficient off time can lead to erratic cycling and retraction of the advancing
servo, slowing down the operation cycle.

Current
The average current is the average of the amperage in the spark gap measured over a
complete cycle. This is read on the ammeter during the process. The theoretical average current
can be measured by multiplying the duty cycle and the peak current (max. current available for
each pulse from the power supply /generator). Avg. current is an indication of the machining
operation efficiency with respect to MRR. The concept of maximum peak amperage that can be
applied to the electrode is an important factor. Before determining the max. Peak ampere age
the frontal area of the electrode minus the area of any flush holes must be determined. This
setting can be fed into the CNC that controls the EDM operation.

Voltage
The voltage used is usually a DC power source of 40 to 400Volts. An AC power source
can also be used but it is usually coupled with a DC rectifier. The pre-set voltage determines the
width of the spark gap between the leading edge of the electrode and the work piece. High
voltage settings increase the gap and hence the flushing and machining.
Gap Size
This is one of the most crucial parts of the EDM system. The size of the gap is governed
by the servo control system whose motion is controlled by gap width sensors. They control the
motion of the ram head or the quill, which in turn governs the gap size. Typical values of the
gap size are between 0.010 to 0.050 mm, although gap sizes as small as of several hundred to
several thousands of micrometre’s can be found depending on the application, current, voltage,
and the die-electric media. To maintain a constant gap size the feed rate should be equal to the
MRR. The gap size governs the possibility of sparking and arcing.

Surface Finish
The EDM process produces surface that contains a layer of recast-spattered metal, which
is usually hard and cracked. Below this recast layer it is possible to have some surface alterations
due to abusive machining. These are more pronounced when we use abusive machining
conditions. The last layer is the heat-affected zone or the annealed layer, which has only been
heated, not melted. The depth of the recast and the heat-affected zone is determined by the heat
sinking ability of the material and the power used for the cut. The altered metal zone influences
the quality of the surface integrity.

Polarity
Polarity refers to the electrical conditions determining the direction of the current flow
relative to the electrode. The polarity of the electrode can be either positive or negative.
Depending on the application, some electrode/work metal combination gives better results when
the polarity is changed. Generally the graphite, a positive electrode gives better wear condition
and negative gives better speed.

Material Removal Rate (MRR)

Achieving an efficient MRR is not simply a matter of good machine settings. It also
includes direct energy dissipated in the EDM process. This energy can be dissipated in three
ways:

The Work Piece: MRR is influenced by the thermal conductivity of the work piece. Copper
for example has a low melting point but it also has a low MRR as it is a good conductor of heat.
On the other hand steel has a high melting point but a low Thermal conductivity hence has a
higher MRR.

In the Gap: Particles in the work gap will contribute significantly to slowing down the MRR.
In the Electrode: The MRR is also influenced by the electrode and the work piece selection.
Duty Factor
This is an important parameter in the EDM process. This is given by the ratio of the ON
time to the total time. If we have a high duty factor then the flushing time is very less and this
might lead to the short circuit condition. A small duty factor indicates a high off time and low
machining rate. Therefore there has to be a compromise between the two depending on the tool
used, the workpiece and the conditions prevailing.
Dielectric –Fluid Functions:
EDM dielectric fluids perform four functions necessary for spark machining. The fluids
provide:

 A known electrical barrier between the electrode and work piece:

 Cooling for the electrode and work-piece
 Cooling for the vaporized material that becomes the EDM chip upon solidification
 A means for removal of the EDM-spark debris from the sparking gap.
De-Ionized Water
De-ionised water absorbs materials that make the water electrically conductive during
the sparking process. As water absorbs materials the dielectric characteristics of the water
change. This also changes the water’s ionization point and it affects the reliability and
repeatability of the sparking process. Given these facts it would appear that deionised water is
not an acceptable dielectric fluid. But wire-cut EDM uses dielectric fluid differently than die-
sinker EDM. In most instances, wire cut machining operations are not performed with the work
piece submerged. Instead, a high velocity flow of fresh deionised water surrounds the electrode
and covers the work piece in the sparking area, it then returns immediately to the collection
system for reprocessing. This process ensures that the deionised water passing through the
sparking area will stay within the acceptable range of the electrical characteristics required for
precise EDM operations. In addition, it makes deionised water the dielectric fluid of choice for
wire-cut operations.

De-Ionized water - Considerations

The following considerations are to be followed while using a deionized water dielectric
system.

The deionizer unit removes dissolved material from water. This material then collects in the
unity, diminishing the capability of the deioniser to produce acceptable water quality. At some
point the deioniser material must be replaced.

 A process known as ion exchange deionises water. This process requires the use of a
resin material. When replacing the deionizer unit, the used material must be disposed of
accordance with environmental requirements.
 Water from the factory source may not be acceptable for filling or replacing water for
the deionised water system. It may be necessary to obtain pre-deionised water.
 Bacteria and fungus can grow in the system and cause problems with the deionizer unit
and filters. If this happens, the system might have to be purged and cleaned before
acceptable water can be produced.
 Machine manufacturer recommendations should always be observed in setting up,
using, and maintaining a deionised water dielectric system.
Filtration
Dielectric fluid needs to be filtered to remove EDM chips and by products that are
produced during sparking. The filter assembly provided with the most EDM machines consists
of a canister that contains the filter with a replaceable element. When the element becomes
clogged and fluid flow through the filter is restricted, the element is removed and replaced.
Disposal of the used filter must be in accordance with proper environmental considerations. It is
a good policy for filter elements used with hydrocarbon fluids, to drain the fluid from the element
prior to disposal. The salvaged fluid can be returned to the machine’s dielectric system. Filters
do not completely remove all particles from the fluid. Filter elements are rated in microns
according to their level of filtration.

Wire-Cut Chip Removal

Chip removal for a wire-cut machine is simple compared to a die-sinker machine. Wire-
cut machines include fluid-flow systems that provide dielectric-fluid flow with pressure to the
top and bottom surfaces of the workpiece. The fluid is introduced into the sparking area by
nozzles that direct flow into the machined opening. Figure 1.9 illustrates the positioning of the
fluid-flow nozzles.

High Velocity Fluid Flow

Wire-cut machining normally requires high-velocity flow of fluid through the sparking
area; the fluid must encapsulate the electrode wire and cover the entire sparking area, as fluid
flows through the sparking area and out of the machined opening, the EDM chips are carried
with it.

Positioning Fluid-Flow Nozzles

Fluid flow nozzles must be positioned very close to the top and bottom workpiece
surfaces for effective fluid control and chip removal. If fluid escapes at either surface, less fluid
will arrive in the sparking area.

Figure 1.9 Wire Cut Fluid Flow Nozzles

 Fluid must be supplied to the sparking area so that the electrode tool wire is completely
surrounded with it. This provides the controlled sparking condition required for wire-cut
machining. The dielectric fluid also cools the electrode tool wire that is heated by the wire’s
sparking and the passage of this spark electricity. Electrode tool wire breakage occurs if fluid
does not properly surround the wire. Wire-cut machining is categorized into two classifications.

 Full-wire plunge machining.

 Partial-wire finish machining.
Full-wire plunge machining creates a sparking area on the electrode wire, Figure
1.10 illustrates this type of machining. In full-wire plunge machining centre enough care needs
to be taken in controlling the fluid flow as it surrounds the electrode tool wire. After establishing
the machined kerf slot, fluid flow is fairly consistent. But at the start of the machining operation
fluid flow may be difficult to establish. If the electrode tool wire enters from a surface outside
of the work piece. Fluid flow may be controllable enough to allow efficient machining
conditions. In this case, reduced sparking energy should be used until the tool wire machines a
slot into the workpiece. Otherwise, wire breakage is likely. A preferred method for starting a
wire-cut machining operation is to provide a pre-drilled start hole in the workpiece to create
positive fluid control by surrounding the electrode tool wire with fluid. In Partial wire finish
machining wire plunge creates less than 1800 sparking area as shown in Figure 1.11. In partial-
wire machining, a curtain of fluid covers the workpiece in the sparking area and encloses the
electrode wire. Chips are carried away with the fluid as it flows past the machined surface. Fluid
flow for partial-wire machining is at a much lower velocity than full-wire machining.
Controlling the dielectric fluid is a major consideration when using partial wire sparking. High
velocity flow is used for full-wire plunge machining, but is not acceptable for partial-wire
machining, which does not have enclosed sparking area.

Figure 1.10 Full-Wire Finish Machining

 Figure 1.11 Partial-Wire Finish Machining
Minimum Wall Thickness for Fluid Control
Loss of fluid in the sparking area also occurs due to insufficient material at the sides of
the machining operation. In most machining operation it is desirable to remove as little of
workpiece material as possible. But in a full plunge machining, a certain wall thickness is
required for efficient fluid control. A narrow wall does not allow the fluid-flow nozzle to seal
the workpiece surface from fluid coming through the nozzle. Therefore a wall thickness of less
than 0.25 inch (6.35mm) should be used with full-plunge machining. Any thinner wall thickness
can result in escaping fluid, increased machining time and possible wire breakage.

Wire EDM Transport System

Wire EDM uses an electrically charged thin brass wire, which is moved by computer
control, close to, but not touching, the part to be cut. The wire and the work piece are either
fully submerged, or the part is vigorously flushed with a dielectric liquid. The small gap creates
a spark, which vaporizes small particles of the work piece as the wire advances. The
disintegrated particles are flushed away by dielectric fluid, and the wire is able to advance
further. The wire itself is traveling – advancing from a large spool, and after use as an electrode,
into a spent wire bin. The travel of the wire is determined by the machine’s computer program.
The complexities of the wire transport system as shown in Figure 1.12 and automatic wire
threader (AWT) both have a direct impact on performance. Since the wire used in the wire EDM
is small and flexible, no more than two times larger than a human hair, threading reliably over
long periods of time without extensive maintenance has been perceived as a problem. However,
the most important feature of a wire EDM machine, in terms of real profitability to the end user,
is the AWT-a reliable AWT system can add many hours of Available foe every week, month
and year. The AWT makes it possible to schedule work more efficiently on the wire EDM
machine based upon the importance rather than the length-time-of cut.
 Figure 1.12 Wire EDM Transport System
Most AWTs use a high-pressure water jet as the main wire transport system between the
upper and lower guides. The entire transport system must be maintained according to the
manufacturer's recommendations. Wire guide types, the complexity of the jet, the cutting
system, drive pulleys and tensioning all have an impact on reliability and performance. When it
becomes possible, depending upon type of application, to operate in an unattended environment
overnights, weekends and holidays, it is realistic to gain hundreds of machining hours per year.
In fact, a highly reliable machining system, operating on a continuing basis will outperform a
less reliable system cutting at high speed. Failure to properly maintain this valuable machine
feature will affect production.
1.6. Materials That WEDM Can Cut:
Carbide
Tungsten carbide, third in hardness to diamond and boron carbide, is an extremely
difficult material to machine. Except for diamond cutting tools and diamond-impregnated
grinding wheels, EDM presents the only practical method to machine this hardened material.
To bind tungsten carbide when it is sintered, cobalt is added. The amount of cobalt, from 6% to
15%, determines the hardness and toughness of the carbide. The electrical conductivity of cobalt
exceeds that of tungsten, so EDM erodes the cobalt binder in tungsten carbide. The carbide
granules fall out of the compound during cutting, so the amount of cobalt binder determines the
wire EDM speed, and the energy applied during the cutting determines the depth of binder that
is removed. When cutting carbide on certain wire EDM machines, the initial first cut can cause
surface micro-cracks. To eliminate them, skim cuts are used. However, at our company, we
have repeatedly cut carbide parts with a single cut. When precision carbide parts are needed,
skim cuts are used. Some older wire EDM machines used capacitors. Since these machines
applied more energy into the cut, there was a greater danger for surface micro-cracking. Then
DC power supply machines without capacitors were introduced, and this helped in producing
less surface damage when cutting carbide. Today, many machines come equipped with AC
power supplies. These machines are especially beneficial when cutting carbide in that they
produce smaller heat-affected zones and cause less cobalt depletion than DC power-supplied
machines. To eliminate any danger from micro-cracking and to produce the best surface edge
for stamping, it is a good practice to use sufficient skim cuts when EDMing high-precision
blanking carbide dies. Studies show that careful skimming greatly improves carbide surface
quality. Durability tests prove that an initial fast cut and fast skimming cuts produce very
accurate high performance dies.

Polycrystalline Diamond
The introduction of polycrystalline diamond (PCD) on a tungsten carbide substrate has
greatly increased cutting efficiency. PCD is a man-made diamond crystal that is sintered with
cobalt at very high temperatures and under great pressure. The tungsten substrate provides
support for the thin diamond layer. The cobalt in PCD does not act as a binder, but rather as a
catalyst for the diamond crystals. In addition, the electrical conductivity of the cobalt allows
PCD to be EDMed. When PCD is EDMed, only the cobalt between the diamonds crystals is
being EDMed. EDM machining PCD, like EDM machining carbide, is much slower than cutting
steel. Cutting speed for PCD depends upon the amount of cobalt that has been sintered with the
diamond crystals and the particle size of PCD. Large particles of PCD require very high open
voltage for it to be cut. Also, some power supplies cut PCD better than others.

Ceramics
Ceramics are poor conductors of electricity. However, certain ceramics are formulated to
be cut with wire EDM.

Cost Savings with WEDM

There are twelve Criteria for Using Wire EDM in Production Applications:

Hard materials: The foremost benefit of wire EDM technology is its ability to cut hard
material. The hardness of the material to be cut does not affect the EDM's speed or ability to cut
it. Wire cutting can be performed on parts with finished dimensions after heat treating with no
additional cost. Typical applications: large series production molds, jigs, fixtures, form tools,
knives.
Exotic Metals: Wire EDM process can cut any material that conducts electricity, including
Carbide, Inconel, Titanium, Haste Alloy, and many others. Typical applications: carbide knives
and wear surfaces, Inconel molds, titanium high performance parts.
Stacking Plates: We can stack thin plates of a specific material and get multiple pieces with a
single cut. Typical applications: custom collet wrenches, flat gears, copper shims.
Speed of EDM Delivery: Production Wire EDM delivery is very rapid as it usually requires
little or no tooling or fixturing. Typical applications: medical and dental prototypes, prototype
gears, prototypes for molded parts.
Racking of Parts: Wire EDM machining allows us to rack parts: this technique is used when
only a particular portion of the work piece needs a complex geometry wire cut into or through
it.
Raw Materials: Wire EDM saves time and money by making possible the use of raw materials
straight from the mill. Bar stock, round stock and plates can all used with little added processing.
A job that would normally require sawing, squaring and milling of stacked plates can be
accomplished in much fewer operations with a wire EDM.
Complex Geometries: Wire EDM is especially beneficial when shapes such as gears, splines,
and long thin slots are required. Any operation requiring such geometries is an excellent
candidate for wire EDM.
Internal Contours: Pipes, gears, pultrusion molds all benefit from wire EDM.
Design Flexibility: Since programs are easily adjusted, prototypes and single parts are
extremely well suited for Wire EDM machining. A part is manufactured very easily since no
hard tooling is involved. Changes to part design can be handled simply and quickly.
CNC 5 Axis Wire Cutting Capability: Complex three dimensional programming systems
enable EDM machines to independently control the top and bottom contour when wire cutting
CNC 5 axis wire. Other applications: tapered pins for molds, extrusion molds.
Burr Free: Wire EDM eliminates secondary deburring operations, reducing the number of steps
required to complete each part. Applications: go/no go gauges, custom tool inserts.
Splines: Wire EDM allows us to cut splines that would not be possible to cut with mechanical
tools. We can make sharp angles with a radius as small as the diameter of the wire.

Applications: machine tools with disposable blades also cut with a wire EDM.
1.7. Benefits of Wire EDM

Efficient Production Capabilities

Because of the precision and high-speed of wire EDM machines, manufacturers are
increasingly discovering that many parts can be more economically produced with wire EDM,
rather than with conventional machining.

Production Reliability
The constant reliability of wire EDM is one of the greater advantages of this
process. Because the programs are computer generated and the electrode is constantly being fed
from a spool (the tool wire electrode is used only once), the last part is identical to the first part.
The cutter wear found in conventional machining does not exist. In addition, tighter machining
tolerances can be maintained without additional cost.

Without EDM Impossible to Machine

As more and more engineers, tool designers, and machinists understand the wire EDM
process, many unique machining processes can be performed that can only be done with wire
EDM.
Reduced Costs
To be competitive in today's market it is important to take advantage of every cost-
saving procedure available. The high-speed cutting wire EDM machines of today have
dramatically reduced costs for many manufactured parts. Conventional machining leaves sharp
edges and often burrs when machined, but a radius can be made with wire EDM without any
additional cost. This eliminates a filing or sanding operation.

Stress-Free and Burr-Free Cutting

Wire EDM is a non-contact, force-free, metal-removing process which eliminates
cutting stress and resultant mechanical distortion. Extremely thin sections can be machined
because the wire electrode never contacts the material being cut. Materials cut with wire EDM
are totally burr-free, and the edges are perfectly straight. Thin parts can be stacked and cut
without leaving any burrs.

Tight Tolerances and Excellent Finishes

The wire path is controlled by a CNC computer-generated program, with part
accuracies up to +/- .0001" (.0025 mm). Dowel holes can be produced with wire EDM to be
either press or slip fit. The extremely fine finish from the standard wire EDM process often
eliminates the need for grinding or other finishing procedures.

Program Files Downloadable

If the parts to be machined are programmed on a CAD system, many job shops
can accept the files directly into their systems. Electronically transmitting these files eliminates
the need for reprogramming the parts.
 CHAPTER 2
LITERATURE SURVEY

Electric discharge machining (EDM) is one of the most efficient manufacturing

technologies used in highly accurate processing of all electrically conductive materials
irrespective of their mechanical properties. It is a non-contact thermal energy process applied
to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies,
and surgical implements, especially for the hard-to-cut materials with simple or complex shapes
and geometries. Applications to molds, tools, and dies are among the large-scale initial
applications of this process. Machining these items is especially difficult as they are made of
hard-to-machine materials, they have very complex shapes of high accuracy, and their surface
characteristics are sensitive to machining conditions. The review of this kind with an emphasis
on tool and die materials is extremely useful to relevant professions, practitioners, and
researchers. This review provides an overview of the studies related to EDM with regard to
selection of the process, material, and operating parameters, the effect on responses, various
process variants, and new techniques adopted to enhance process performance. This chapter
reviews research studies on the EDM of different grades of tool steel materials. This chapter (i)
pans out the reported literature in a modular manner with a focus on experimental and theoretical
studies aimed at improving process performance, including material removal rate, surface
quality, and tool wear rate, among others, (ii) examines evaluation models and techniques used
to determine process conditions, and (iii) discusses the developments in EDM and outlines the
trends for future research.
In recent years, rapid developments in aerospace, medical instruments, transportation,
and many other industrial sectors increased the need for new materials with favorable
characteristics. In addition to unique characteristics, most modern materials need special
manufacturing processes to enable them to be machined with ease [1,2]. Most of these materials
are usually difficult to cut by conventional manufacturing processes [3–7]. The unique
characteristics of these hard-to-cut materials increase their applications, which further drive
manufacturers to explore new machining processes with reasonable cost and high precision
[8,9].
Tool steels and other tool materials (e.g., carbides) are such widely used hard-to-cut
materials because of their high hardness and abrasion wear resistance, in addition to their
ability to withstand high load and to operate in rapidly changing temperatures [6]. Tool steels
have a wide range of applications, including stamping and metal-working dies, cutting tools,
hammers, and machine parts [10]. Applications of these tools in the manufacturing sector is
very large; thus, there exists huge machining requirements of tools, tooling, dies, and molds
[11]. Before being put to use, these steels are subjected to heat treatment to meet the required
properties for specific application [12,13]. In addition to iron and carbon, tool steels have in
them other elements (e.g., Cr, W, V, Mo, etc.) to increase their strength, hardness, hot strength
and hot hardness, and wear resistance. Although these steels can be machined by conventional
methods, they come with serious concerns with regard to very poor tool life and part accuracy
[14].
 Electric discharge machining (EDM) is one of the most advanced manufacturing
methods used to successfully machine conductive hard-to-cut materials [8,15–19]. EDM is the
process of choice to machine hard-to-cut materials widely used in modern industries to facilitate
accurate machining [20–25], complex shape machining, and better surface integrity. The
process is utilized to machine electrically conductive materials by applying repetitive sparks
between electrode and workpiece. Unlike in mechanical machining, no deforming force is
required between the electrode and the workpiece, and the machining takes place without actual
contact between them [23,26–28]. There are a large number of variants of the EDM process
such as sinking EDM, wire EDM, micro-EDM, powder-mixed EDM, and dry EDM; all of
these possess work on the same mechanism of material removal. Developments of variants make
the process more versatile and suitable for relatively big and micro-scale machining areas.
Several review papers related to EDM were published in recent years such as references [29–
35], among others. Furthermore, some other articles presented a discussion of specific
objectives; for example, Barenji et al. [36] developed a model for prediction of material
removal rate (MRR) and tool wear rate (TWR) for the EDM of AISI D6 tool steel. They
reported that higher values of pulse-on time resulted in higher MRR and lesser TWR. Long et
al. [37] used powder-mixed EDM for machining die steels. Titanium powder was used for
mixing, and surface quality was analyzed. It was revealed that the quality of surface layer was
improved at optimal parameters. Shabgard et al. [38] studied the effects of the key input variables
of wire EDM of ASP30 tool steel. The output responses under consideration were MRR and
surface roughness. The results revealed that an increase in spraying pressure of dielectric fluid led
to a higher MRR and surface roughness. EDM of AISI M42 high-speed tool steel alloy was
conducted to study the effect of major input parameters on MRR. It was revealed that tool
polarity was the most influential factor and, at negative polarity, maximum MRR was achieved.
P20 tool steel was machined using wire EDM, and pulse-on time, pulse-off time, peak current,
and spark gap voltage were varied. The output responses under study were kerf width and
MRR. The best combination of parameters was reported to achieve maximum MRR [39].
Sharma and Sinha [40] applied rotary-EDM to machine AISI D2 tool steel using a copper
electrode. MRR, TWR, and machining rate were studied by varying input parameters (peak
current, voltage, duty cycle, and electrode rotation speed). Bahgat et al. [41] conducted
experiments to study the effect of major input variables on MRR, electrode wear ratio, and
surface roughness while machining H13 die steel. It was reported that higher MRR and lower
electrode wear rate were achieved using a copper electrode, whereas lower surface roughness
was attained with a brass electrode. Gopal et al. [42] compared the performance of unprocessed
and equal channel angular pressing (ECAP)-processed copper electrode while machining AISI
H13 tool steel using EDM. It was reported that the triple-ECAP-passed electrode gave better
machining quality. Despite many existing review papers, to the best of authors’ knowledge,
there is no study that reviewed the EDM process specifically for tool and die steels. Since tool
and die steels have usage in a wide range of applications and they are difficult to cut with the
conventional manufacturing processes, non-conventional processes such as EDM are becoming
prevalent for their machining. Generally, one of the largest uses of the EDM process is in tool-,
die-, and mold-making. All these industries mostly use various kinds of tool steels. EDM
remains one of the most popular processes used for their fabrication.
 Figure 2.1 shows the EDM processes and their main process parameters and output
(performance) measures.

Figure 2.1. The processes of electric discharge machining (EDM) and their process
parameters and performance measures.

Various Grades of Tool Steels

Steels can be categorized into four groups, namely, stainless steel, tool steel, carbon steel, and
alloy steel. Each of these groups has its own characteristics which make it suitable for specific
applications. Tool steels are mainly employed for making cutting and metal-working tools
[12]. In order to meet the required conditions these tools encounter under service conditions,
tool steels must have many properties such as the ability to withstand high load, the ability to
operate in rapidly changing temperatures, high abrasive resistance, etc. Normally, the tool steels
are used in hardened conditions by heat treatment, and they are subsequently tempered to meet
the required properties for specific application [12]. Tool steels are high-hardness and abrasion-
resistant alloy steels. In addition to iron and carbon, tool steels include many other elements to
increase hardness and wear resistance and hot strength and hot hardness. Furthermore, they
also possess adequate toughness which can be achieved by tempering, which is performed
subsequent to hardening. Applications of tool steels include stamping and extrusion dies,
cutting tools, hammers, and machine parts [10]. Properties of widely and recently used different
grades of tool steels, as well as the EDM processes considered for each grade, are summarized
in Table2.1.
 Table 2.1. Details of various EDM processes used by researchers for different grades of
tool steels

Different Grades and Composition (Weight %) Properties

Corresponding Machining
Operations

AISI D2 C 1.5, Si 0.3, Mn 0.3, Mo High-carbon and high-

1.0, Cr 12.0, Ni 0.3, V 0.8, chromium tool steel. It has
Die sinking EDM [85,104–110]. Co 1.0. high resistance to wear and
Wire EDM [111–113] abrasion. D2 grade is heat-
treatable steel with hardness
Powder-mixed EDM [114–116]. in the range 55–62 HRC. Its
corrosion resistance depends
on the percentage of
chromium [117].

AISI D3 C 2.00, Si 0.30, Mn 0.30, Cr High-carbon, high-

12.00 chromium tool steel. It has
Die sinking EDM [118]. excellent resistance to wear
Wire EDM [119]. and abrasion and has good
dimensional stability and
high compressive strength.
Its hardness is in the range
of 58–64 HRC [120].

AISI D5 C 1.53, Si 0.89, Mn 0.46, Cr Similar to other grades in

12.00, Mo 1.00, Ni 0.384 group D, D5 has high carbon
Wire EDM [121,122]. and high chromium content;
it is the most commonly
used steel among the group
D steels [123].

AISI D6 Cr 12.5, C 2.05, W 1.3, Mn In addition to high carbon

0.8, Si 0.3 and high chromium
Die sinking EDM [124]. contents, D6 tool steel is
alloyed with tungsten. D6
steel has high compressive
strength, high wear
resistance, high surface
hardness, and good
hardening stability [125].

AISI H11 Cr 4.75–5.50, Mo 1.10– H11 grade is one of the most

1.75, Si 0.80–1.20, V 0.80– commonly used chromium
Die sinking EDM [109,126]. 1.20, C 0.32–0.45, Ni 0.3, hot-work steels. It has low
Dry EDM [78,127]. Cu 0.25, Mn 0.20–0.50, P carbon content and has good
0.03, S 0.03 toughness and deep hardness
Powder-mixed EDM [116,128– due to air quenching from
131]. heat treatment [133].

Micro-EDM [132].

AISI O1 C 0.85–1.00, Mn 1.00–1.40, O1 is oil-hardening tool

Si 0.50, Cr 0.40–0.60, Ni steel. It has good
Die sinking EDM [76]. 0.30, W 0.40–0.60, V 0.30, machinability and
Wire EDM [134]. Cu 0.25, P 0.0, S 0.03 dimensional stability in
hardening. It also has a good
Powder-mixed EDM [135,136]. combination of high surface
hardness and toughness after
hardening and tempering.
O1 grade has good
resistance to wear and
abrasion due to its content of
tungsten and chromium
[137].

AISI O2 OHNS: C 0.82, Si 0.18, Mn O2 grade is oil-hardening

0.52, Cr 0.49, V 0.19, Mo tool steel. It has good
Powder-mixed EDM [116]. 0.13, Ni 0.05; durability, excellent wear
resistance, and an ability to
hold a good cutting edge
[138].

AISI M2 C 0.78–1.05, Cr 3.75–4.50, M2 grade is molybdenum-

W 5.50–6.75, Mo 4.50–5.50, based high speed steel
Die sinking EDM [139–141]. V 1.75–2.20. (HSS). It is a medium
Wire EDM [142]. alloyed HSS. It has good
machinability, well-balanced
toughness, wear resistance,
and red hardiness properties
[143].

SKD11 C 1.40–1.60, Si Max 0.40, SKD 11 is high-carbon and

Mn Max 0.60, P Max 0.030, high-chromium alloy steel.
Die sinking EDM [144–147]. S Max 0.030, Cr 11.0–13.0, It has high hardness and a
Wire EDM [148–151]. Mo 0.80–1.20, V 0.20–0.50. tempering hardening effect.
It also has good resistance to
Dry EDM [103,152]. wear, quenching, and less
deformation. Currently, it
Powder-mixed EDM
has the best wear resistance
[54,136,153–155].
of alloy tool steel [156].

SKD61 Die sinking EDM [157]. C 0.35–0.42, Si 0.80–1.20, KSD61 is hot-work steel; it
Powder-mixed EDM Mn 0.25–0.50, P Max 0.030, has high creep, temperature
[136,158,159]. S Max 0.020, Cr 4.80–5.50, fatigue resistance, and high
Mo 1.00–1.50, V 0.80–1.15 toughness. It also has a good
ability to be polished and
 good thermal conductivity
[160].

P20 Die sinking EDM [161– C 0.28–0.40, Si 0.20–0.80, P20 tool steel is a chrome-
164]. Dry EDM [165]. Powder- Mn 0.60–1.00, P Max. moly alloy steel with a
mixed EDM [166]. 0.030, S Max. 0.030, Cr carbon content of
1.40–2.00, Mo 0.30–0.55. approximately 0.35 to 0.40.
P20 has good mirror-polish
ability and less texture,
making finishing easier. It
distributes a uniform
hardness level even across
large blocks [167].

BÖHLER W300 C 0.36, Si 1.1, Cr 5.0, Mo BÖHLER W300 is hot-work

Die sinking EDM [168–170]. 1.3, V 0.4 tool steel and it has high
impact strength and
excellent hot tensile
properties.
EN 31 C 0.9–1.2, Si 0.1–0.3, Mn EN 31 is a high-carbon alloy
Die sinking EDM [23]. 0.3–0.7, Cr 1–1.6, S Max steel. It has high hardness
Powder-mixed EDM [61]. 0.025 and P Max 0.025. with compressive strength.
Moreover, it has high
resistance against wear and
abrasion.
ASP 2023 C 1.28, Cr 4.1, Mo 5.0, W ASP 2023 is a high-alloy
Die sinking EDM [171]. 6.4, V 3.1 high-speed steel. It has
Wire EDM [172]. dimension and shape
stability during heat
treatment. It has good
toughness even for large
dimensions. ASP 2023 has
high hardness and good
wear resistance [173].
C45 C 0.43–0.50, Si 0.17–0.4, C45 is a medium carbon
Die sinking EDM [174]. Mn 0.50–0.8 steel. It has high strength
Wire EDM [175]. and hardness. It features
extreme size accuracy,
straightness, and
concentricity combined with
minimal wear in high-speed
applications [176].
DC 53 C 0.95, Si 1.0, Mn 0.4, Cr DC53 has exceptional
Wire EDM [177,178]. 8.0, Mo 2.0, V 0.3 toughness, wear resistance,
compressive strength, and
temper resistance. It also has
excellent machining
characteristics [179].
DIN 1.2379 C 1.50, Si 0.30, Cr 12.0, Mo This grade has high abrasive
Die sinking EDM [180–182]. 0.80, V 0.80 resistance, adhesive wear
resistance, and compressive
strength. It also has good
toughness and good
dimensional stability [183].
DIN 1.2738 C 0.4, Mn 1.5, Cr 1.9, Ni This grade has good
Die sinking EDM [184]. 1.0, Mo 0.22 toughness, wear resistance,
Micro-EDM [185]. stability in hardness, and
high hardenability
DIN 1.2714 C 0.50–0.60, Si 0.10–0.40, DIN 1.2714 has good
Die sinking EDM [186]. Mn 0.65–0.95, Cr 1.0–1.2, P hardenability and uniform
max. 0.03, S max. 0.03, V hardness over sections with
0.07–0.12, Ni 1.50–1.80, big dimensions.
Mo 0.45–0.55 Furthermore, it has good
strength and toughness in
addition to its tempering
resistance and dimensional
stability [187].
DIN 1.2080 C 2.00–2.35, Mn 0.60, Si DIN 1.2080 is high-
Die sinking EDM [182]. 0.60, Cr 11.00–13.50, Ni carbon/chromium tool steel.
0.30, W 1.00, V 1.00, Cu It has very high wear
0.25, P 0.03, S 0.03 resistance and compressive
strength. It can be hardened
with a very slight change in
size.
AISI 4340 C 0.38–0.43, Si 0.15–0.35, AISI 4340 is a heat-treatable
Die sinking EDM [188]. Mn 0.6–0.8, P 0.035, S 0.04, and low-alloy steel
Cr 0.7–0.9, Ni 1.65–2.0, Mo containing chromium,
0.2–0.3 nickel, and molybdenum. It
has high toughness and
strength in the heat-treated
conditions [189].
S390 C 1.64, Cr 4.80, W 10.40, This material has the ability
Wire EDM [148]. Co 8.00, V 4.80, Mo 2.00, Si to maintain its strength and
0.60, Mn 0.30 hardness level under
extremely high cutting
temperatures.
M238 HH C 0.36 0, Si 0.28, Mn 1.52, It is hardened and tempered
Die sinking EDM [74]. P 0.008, S 0.001, Cr 1.88, plastic mold steel. There is
Mo 0.22, Ni 0.95, Al 0.021 reduction of hardness in the
center of large sizes due to
the Ni-addition.
Vanadis-4E C 1.4, Si 0.4, Mn 0.4, Cr This grade has very good
Wire EDM [190]. 4.7, Mo 3.5, Va 3.5 ductility, high
abrasive/adhesive wear
resistance, and high
 compressive strength.
Moreover, it has good
dimensional stability during
heat treatment, good
through-hardening
properties, and temper back
resistance [191].

Earlier studies were also conducted to investigate the relationship between processes
and performance parameters [54,142]. The main researches in optimizing process parameters
of EDM machining are summarized in Table 2.2.

No. Authors Process Process Machining Remarks

parameters performance

1 (Younis et EDM Is, EM, and CR and RS SR was higher when using
al., 2015) MC Dura graphite than when using
[182] Poco graphite. As pulse
current increases, micro-
cracks increase; soft
machining exhibited higher
residual stresses than medium
and rough machining. Poco
graphite exhibited higher
residual stresses compared
with Dura graphite electrode.

2 (Valaki and Die Is, Vg, Ton, MRR, EWR, The waste vegetable oil-based
Rathod 2015) sinking and Tof and TWR bio-dielectric fluid can be used
[74] EDM as an alternate to hydrocarbon-
machine , water-, and synthetic-based
dielectric fluids for EDM.

3 (Zhang et al. EDM PD and RE, D_plas, The MRR and energy
2014) [197] PoW and RE efficiency were much higher
with short pulse durations than
with long pulse durations. The
depth–diameter ratio of the
crater was higher when the
workpiece was positive.

4 (Sudhakara W EDM Ton Toff, SR The ranges of process

and Prasanthi Vs, Ip, WT, parameters for wire EDM
2014) [190] and DP were established as follows:
pulse-on time 108–128 µs,
pulse-off time 47–63 µs, peak
current 11–13 A, voltage 18–
 68 V, wire tension 2–8 g,
water pressure 8–14.

5 (Aich and EDM I, Ton, and MRR and SR The optimal parameters (I,
Banerjee Toff Ton, and Toff) to maximize
2014) [139] the MRR were 12.0 A,
153.9865 µs, and 50.0000 µs,
respectively, and those to
achieve the best SR were 3.0
A, 200.000 µs, and 126.8332
µs, respectively.

6 (Balasubrama EDM Ip, Ton, DP MRR, TWR, For EN-8 material, the mean
nian and and D_tool and SR MRR value was (72.4 mm3
Senthilvelan /min), it was higher for the cast
2014) [118] electrode than for the sintered
electrode. The TWR was
(12.73 mm3 /min); it was
lower for the cast electrode
than for the sintered electrode.
For die steel D3, the mean
value of MRR was higher for
the cast electrode than for the
sintered electrode. The TWR
was marginally lower for the
cast electrode than for the
sintered electrode. The mean
value of SR was marginally
lower for the sintered
electrode than for the cast
electrode.

7 (Sahu, EDM Ip, Ton, τ, MRR, TWR, The values of discharge

Mohanty et and Dp SR, and r1 current (Ip), pulse-on time
al. 2013) /r2 (Ton), duty factor(τ), and
[107] flushing pressure (Fp) that
achieved the best quality were
7 A, 200 µs, 90%, and 0.4
kg/m2, respectively. The
optimal obtained response
parameters were MRR =
13.9600 mm3 /min, TWR =
0.0201 mm3 /min, Ra =
4.9300 µm, and circularity =
0.8401.
8 (Klocke et al. EDM I, PD, and MRR and The discharge current was the
2013) [170] GG TWR main parameter effect on the
MRR and the discharge
duration was the main
parameter effect on the TWR.
There was no direct link
between the grain size and the
two response parameters MRR
and TWR. MRR increases as
the current increases and it
decreases as the pulse duration
and electrical conductivity of
graphite grade increase.
Relative TWR slightly
decreases as the current
increase and slightly increases
as the electrical conductivity
of graphite grade increase,
whereas it sharply decreases as
pulse duration increases.

9 (Shabgard et EDM Is and Ton PFE Plasma flushing efficiency

al. 2013) increases as pulse current
[126] increases and it decreases as
pulse-on time increases.
Recast layer thickness
increases as pulse-on time
increases.

10 (Fan, Bai et W EDM- C T and SR Best surface roughness and the

al. 2013) HS minimum achievable
[198] maximum processing
thickness were obtained upon
selecting a capacitance that
achieved triple the charging
time constant equal to pulse
duration.

11 (Srivastava EDM Is, Ton, τ, MRR, EWR, EWR and surface roughness
and Pandey, and Vg and SR were significantly lower in the
2012) [141] ultrasonic assisted
cryogenically cooled copper
electrode (UACEDM) process
than in the conventional EDM
process and MRR was
approximately the same as for
conventional EDM. Surface
integrity of the workpiece
machined by UACEDM was
 better than that machined by
the conventional EDM
process. In UACEDM, the
density of cracks increases as
the discharge current
increases. Induced stress
increases as pulse-on duration
and crack formation increase.

12 (Teimouri EDM DE, H, and MRR and SR The rotary tool electrode
and Baseri w improved the machining
2012) [196] performance. The magnetic
field reduced the inactive
pulses and helped the
ionization. As rotational speed
increases, Ra decreases.

13 (Kumar and EDM Ip, Ton, and µH Machining conditions

Batra 2012) Tof allowing material transfer (of
[116] tungsten and carbon to the
workpiece surface) by EDM
were at a discharge current less
than 5 A, shorter pulse-on time
less than 10 µs, and longer
pulse-off time more than 50 µs
with negative polarity of the
tool electrode. The most
significant factor for surface
modification was peak current.

14 (Sivapira et EDM Ip, PD, DL, S_green The optimal machining

al. 2011) and DF performance for green EDM
[194] was with peak current = 4.5 A,
pulse duration = 261 µs,
dielectric level = 40 mm, and
flushing pressure = 0.5 kg/cm2
.

15 (Çayda¸s et Wire PD, V, DP, TWL and The developed approach

al. 2009) EDM and S-wire Avr_SR greatly improved the surface
[121] roughness and white layer
thickness in wire EDM.

16 (Lin et al. EDM P, Ip, PD, MRR and SR The MRR of magnetic force-
2009) [157] IH, V, and assisted EDM was almost
Vs three times as large as the
value for standard EDM.
Employing magnetic force-
assisted EDM improved the
 lower relative electrode wear
ratio (REWR) from 1.03% to
0.33% and reduced the SR
from Ra 3.15 to 3.04 µm on
average. Discharge craters
were bigger and deeper, and
micro-cracks were more
common in standard EDM
than that magnetic force-
assisted EDM. In the magnetic
force-assisted EDM process,
MRR was significantly
affected by polarity and peak
current and SR was
significantly affected by peak
current. The optimal
parameters which maximized
MRR were negative polarity,
peak current = 5 A, auxiliary
current = 1.2 A, pulse duration
= 460 µs, no-load voltage =
120 V, and servo reference
voltage = 10 V. The optimal
parameters which achieved
minimum SR were positive
polarity, peak current = 20 A,
auxiliary current = 0.8 A, pulse
duration = 460 µs, no-load
voltage = 200 V, and servo
reference voltage = 10 V.

17 (Wu et al. EDM Ip, PD, V, MRR and SR Adding 30 g/L of Span 20 to
2009) [159] and Vg kerosene increased the MRR
by 40%. Selecting proper
working parameters improved
MRR by 85%. SR was not
deteriorated even at MRR.
Adding Span 20 (30 g/L)
decreases both the
concentrated discharge energy
and the unstable discharge
phenomenon. The thickness of
recast layer on the workpiece
of kerosene was less than the
thickness of pure kerosene.
The surfactant increased the
conductivity of kerosene and
shorted the delay time, thus
 improved the machining
efficiency

18 (Matoorian et EDM IN, Ton, MRR The factors most influencing

al. 2008) Toff, V, S, the cost-effectiveness of the
[193] and W EDT process were intensity,
spindle speed, servo, and
pulse-on time in the following
combination: 6 A, 50 µs, 20
µs, 120 V, 30 V, and 40 rpm,
respectively. The actual and
predicted values of MRR were
0.023 and 0.021, respectively.

19 (Haron et al. EDM I, EM, and MRR The copper electrode achieved
2008) [192] D_tool higher MRR than the graphite
electrode. It was
recommended to use the
copper electrode for rough
cutting and the graphite
electrode for finish cutting

20 (Haddad and Wire P, Toff, V, MRR The only influential design

Tehrani EDM and w factors and interaction effects
2008) [119] of machining parameters on
the MRR in the cylindrical
wire electrical discharge
turning process were power,
voltage, pulse-off time, and
spindle rotational speed.

21 (Kansal et al. Powder- I, Ton, Toff, TD The simulation results showed

2008) [114] mixed DE, and that PMEDM produced
electric PCH smaller and shallower craters
discharg than EDM under the same set
e of machining conditions.
machinin
g
(PMED
M)

22 (Kanlayasiri Wire Ton, Toff, SR The main parameters of wire

and EDM Ip, and WT EDM affecting the SR of
Boonmung DC53 die steel were pulse-on
2007) time and pulse-peak current.
[177,178] The SR increases as the pulse-
on time and pulse-peak current
increase.
23 (Kansal et al. Powder- Ip, Ton, MRR MRR in powder-mixed EDM
2007) [115] mixed Toff, was significantly affected by
EDM PCON, GN, peak current, concentration of
and NF the silicon powder, pulse-on
time, pulse-off time, and gain.
Among all, peak current and
concentration of silicon
powder were the parameters
most influencing MRR. The
optimum c parameters were
peak current = 10 A, powder
concentration = 4 g/L, pulse-
on time = 100 µs, pulse-off
time = 15 µs, and gain = 1
mm/s.

24 (Kiyak and EDM Is, Ton, and SR The SR increases as pulsed

Cakır 2007) Tof current and pulse time
[164] increase. SR decreases as
current and pulse time
decrease and pulse pause time
increases. For rough EDM
machining, the machine power
should be 25% of the produced
power with current, pulse
time, and pulse pause time of
16 A, 6 µs, and 3 µs,
respectively. For finish
machining, the machine had
50% of produced power with
current, pulse time, and pulse
pause time of 8 A, 6 µs, and 3
µs, respectively.

25 (Tzeng and EDM V, Pd, τ, Ip, Precision and 81.5% of the high-speed EDM
Chen 2007) PCON, accuracy of process variance was due to
[154] regular the high- pulse time, duty cycle, and
distance for speed EDM peak value of discharge
electrode current. The best parameter
lift, time combinations achieving
interval for precision and accuracy of the
electrode high-speed EDM process were
lift, and open-circuit voltage of 120 V,
powder size pulse duration of 12 µs, duty
cycle of 66%, pulse-peak
current of 12 A, powder
concentration of 0.5 cm3 /L,
regular distance for electrode
 lift of 12 mm, time interval for
electrode lift of 0.6 s, and
powder size of 40 µm

26 (Zarepour et EDM Ton, I, and TWR Pulse-on time, current, and

al. 2007) V pre-EDM roughing as factors,
[186 along with pulse-on
time/current, pulse-on
time/pre-EDM roughing, and
current/pre-EDM roughing as
interactions, were found to
have significant effects on
electrode wear of the EDM
process of DIN 1.2714.

27 (Yilmaz et al. EDM Is, PD, PI, EWR, better Providing a selection tool
2006) [188] FR, and GC SR, and ER enables an unskilled user to
select necessary parameters
which achieve less electrode
wear, better surface quality,
and high erosion rate for both
finish and rough machining.

28 (Wu et al. EDM P, PD, V, SR The surface roughness of the

2005) [158] Vg, PCON, workpiece in the EDM process
and SCON was improved by adding
surfactant and aluminum
powder to the dielectric fluid.
The EDM parameters which
achieved optimal surface
roughness (0.172 µm) were Al
powder concentration of 0.1
g/L, positive polarity, peak
current of 0.3 A, peak duration
of 1.5 µs, and surfactant
concentration of 0.25 g/L. The
gap distance was increased by
adding aluminum powder or
surfactant to the EDM
dielectric fluid. Dielectric
mixed with both aluminum
powder and surfactant
achieved an optimally thin
recast layer. The mixture also
improved the SR by 60%
compared to the SR under
normal dielectric.
29 (Kansal et al. Powder- Ton, τ, Ip, MRR and SR MRR increases as the
2005) [61] mixed and PCON concentration of the silicon
EDM powder increases. SR
decreases as the concentration
of the silicon powder
increases. Peak current and
concentration of the silicon
powder were the parameters
most affecting MRR and SR.
MRR increases and SR
decreases as the combination
of peak current and
concentration increase.

30 (Amorim and EDM Is, PD, PI, MRR, WWR, The maximum MRR of 8 mm3
Weingaertner V, P, and and SR /min was obtained at a
2005) [161] G_mod discharge current of 8 A and a
discharge duration of 50 µs,
with positive electrode
polarity and a generator under
iso-energetic mode. The
minimum average SR of 0.6
µm was obtained at a
discharge current of 3 A,
discharge duration of 12.8 µs,
negative electrode polarity,
and generator under iso-
energetic mode. The
volumetric relative wear for
EDM with a negative
electrode polarity was much
higher than that with positive
electrode polarity

31 (Hasçalýk W EDM PD, V, S- SR and MS The thickness white layer was

and Çayda¸s wire, and proportional to the magnitude
2004) [122] DP of the energy impinging on
that surface. The density of
cracks in the white layer and
SR increase as the pulse
duration and open-circuit
voltage increase. Dielectric
fluid pressure and wire speed
did not have much of an
influence on SR. The surface
of all workpieces was harder
than the bulk material, while
the heat-affected zone was
 softer in quenched and
tempered workpieces

32 (Kunieda et Dry G and Gain MRR The monotonous oscillation

al. 2004) EDM using a piezoelectric actuator
[103] was not useful in dry EDM.

33 (Singh et al. EDM Is and EM MRR, Among copper, copper

2004) [23] D_over, tungsten, brass, and
EWR, and aluminum, copper and
SR aluminum electrodes offered
higher MRR and SR during
machining of En-31 work
material in EDM, where the
electrodes of these two
materials produced low
diametrical overcut. The
copper–tungsten electrode
offered low values of SR at
high discharge currents.
Copper and copper–tungsten
electrodes offered low EWR.
In contrast, brass resulted in
the highest EWR. Among the
four electrode materials,
copper was the best to machine
En-31 material.

34 (Lin et al. W EDM Ton, Toff, Avg_CS and The parameters most affecting
2000) [54]; Ip, τ, Vp, S- G-InI the average cutting speed
Puri and wire, WT, during rough cutting were
Bhattacharyy Vs, DP, and pulse-on time, pulse-off time,
a 2003) [142] F and pulse-peak current, and
those during trim cutting were
pulse-on time and constant
cutting. The parameter most
affecting the SR during rough
cutting was pulse-peak
current, and those during trim
cutting were pulse-on time,
pulse-peak voltage, servo
spark gap set voltage,
dielectric flow rate, wire tool
offset, and constant cutting
speed. The factors most
affecting geometrical
inaccuracy due to wire lag
during rough cutting were
pulse-on time, pulse-off time,
 pulse-peak current, and pulse-
peak voltage, and those during
trim cutting were wire tension,
servo spark gap set voltage,
wire tool offset, and constant
cutting speed.

35 (Guu et al. EDM Is, Ton, and T_RL, SR, The recast layer becomes
2003) [105] Tof and σres thicker as the pulse current and
pulse-on duration increase. As
the peak current is achieved,
the melting of the material and
damage of the surface and
subsurface area increase.

36 (Ghoreishi EDM A, w, LF, MRR, TWR, High-frequency vibration had

and Atkinson and HF and SR a notable effect on the MRR.
2002) [135] The combination of low-
frequency vibration and
electrode rotation did not give
a satisfactory effect on MRR.
The combination of ultrasonic
vibration and electrode
rotation led to an increase in
MRR. The combination of
high-frequency vibration and
electrode rotation was the best
for the finishing cut. In the
semi-finishing cut, the vibro-
rotary EDM increased MRR
by 35% and 100% compared
to vibratory and rotary EDM,
respectively.

37 (Kunieda and Dry The MRR and waviness could

Furudate EDM be improved by increasing the
2001) [152] wire winding speed and
decreasing the actual depth of
cut.

After reviewing the research work related to tool steel machining using the EDM process,
it can be found that the majority of studies investigated the effect of the operating parameters on the
performance parameters of MRR, EWR, and surface quality. Other bodies of research were
conducted to investigate, solve, or study other issues, such as the electrode shape and its
movement, the effect of the EDM process on the tool steel properties and machined surface, as
well as combined and hybrid processes, and the effect of various dielectric fluid used in the
process, among others. Researchers paid more attention to the sinking EDM and micro-EDM
processes to obtain optimal and near-optimal operating parameters, which may be attributed to
the popularity of these two processes. Figure 2.2 shows the percentages of the EDM processes
utilized for studying tool steel machining.

Figure 2.2. Percentage of research related to EDM processes.

This review on the state-of-the-art studies of the EDM processes of tool steel led to the
following conclusions:

• According to the general agreement of the results, the main factors influencing the MRR
of different tool steel grades in EDM are the discharge current and the pulse-on time. The
gas pressure and electrode rotation speed also have a significant influence on the MRR.
Furthermore, the MRR can be improved by using an electrode material with high electrical
conductivity. Using powder-mixed EDM significantly affects the MRR.
• According to major observations by the researchers, low SR is achieved at lower peak
current and pulse-on duration. Furthermore, the medium value of peak current, along with
minimum possible pulse-on time, can minimize surface crack density. The review
revealed that the SR is increased with higher values of pulsed current and pulse-on time,
whereas better surface finish is achieved with lower current, lower pulse-on time, and
relatively higher pulse-off time. Long-duration pulses cannot meet the machining
requirements during finish machining with high requirements in SR. Furthermore,
applying a magnetic field leads to an improvement in surface quality.
• Table 2.3 shows the general effect of major operating parameters on key performance
measures.
 Table 2.3. General effect of major operating parameters on key performance measures

• The review revealed that surface cracks are influenced by the pulse current. Furthermore,
a reduction in pulse-on duration suppresses the formation of surface cracks.
• The review revealed that waste vegetable oil-based bio-dielectric fluid can be used as an
alternate to hydrocarbon-, water-, and synthetic-based dielectric fluids for EDM.
Furthermore, the use of a powder-mixed dielectric in EDM reduces the SR, crater diameter,
crater depth, and the white-layer thickness; it also significantly reduces the surface
heterogeneity.
• The studies also divulged that a significant amount of material is transferred from the
powder suspended in the dielectric medium to the work material. The most significant
factor for this phenomenon of surface modification is the peak current.
• The review also revealed that ultrasonic action has a significant influence on the
performance of the EDM process. The surface integrity is better in an ultrasonic-assisted
process than in conventional EDM.
• Applying a magnetic field reduces inactive pulses, including arcing, short circuit, and open
circuit, in addition to helping in the ionization. Using a magnetic field also leads to an
improvement in surface quality.
• The review revealed that, for thermal profiling, the gauss heat source was closer to the
actual EDM process than the point heat source, circular heat source, and other heat source
types.
• The compositions of generated aerosol depend on the composition of the electrode
materials and on the boiling points of its constituents.
• According to a general observation by the researchers, the particle size in the dielectric fluid
affects the surface quality of the machined surface. More improvements in the SR can be
achieved using a smaller particle size. However, particle size has the opposite effect on
the recast layer, whereby a smaller particle size leads to a thicker recast layer in the EDM
machined surface. Despite the existing studies on this topic, more studies are still
needed to assess the effect of adding different available powder types in the EDM of
different grades of tool steel.
• In the EDM process, particle agglomeration is reduced after surfactant molecules cover the
surface of debris in the dielectric fluid. Adding a co-surfactant to the dielectric increases
the conductivity of the dielectric and improves the machining efficiency. Furthermore, it
improves the MRR of the EDM process.
 CHAPTER 3
METHODOLOGY
In the present chapter the methodology used for obtaining better response parameters is
briefly discussed. In modern industrial environment a numerous kind of Investigations have
been done for the improvement of product quality in the field of manufacturing. Some have few
factors to be considered, some have many. While there are others, that demand factors to have
mixed levels. A vast majority of experiments however fall in the category where all factors
possess the same number of levels. In the conventional technique of varying one factor at a time,
lot of experimental data can be obtained. This way of experimentation not only consumes lot of
time but also poses a challenge to the investigator for deriving appropriate conclusion from the
huge experimental data. Design of Experiments (DOE) is at ever rescue for planning systematic
experimentation and arriving at meaningful conclusion without being inundated in huge set of
experimental data. DOE is an experimental strategy in which effects of multiple factors are
studied simultaneously by running tests at various levels of factors. There are number of
statistical techniques available for engineering and scientific studies. In the present investigation
a multi objective optimization method taguchi based utility and AHP is employed for optimizing
the control parameters.

3.1. Design of Experiments (DOE)

Design of Experiments is a powerful statistical technique introduces by R.A. Fisher in

England in the 1920’s to study the effect of multiple variables simultaneously. The DOE using
Taguchi approach can be economically satisfy the needs of problem solving and product/process
design optimization projects. DOE is a technique of defining and investigating all possible
combinations in an experiment involving multiple factors and to identify the best combination.
In this different factor and their levels are identified. Design of Experiments is also useful to
combine the factors at appropriate levels, each with the respective acceptable range, to produce
the best results and yet exhibit minimum variation around the optimum results. Therefore, the
objective of a carefully planned designed experiment is to understand which set of variables in
a process affects the performance most and then determine the best levels for these variables to
obtain satisfactory output functional performance in products.

Advantages of Design of Experiments (DOE)

 Number of trails is significantly reduced.

 Important decision variables which control and improve the performance of the product
or the process can be identified.
 Optimal setting of the parameters can be found out.
 Qualitative estimation of parameters can be made.
 Experimental errors can be estimated.
 The effect of parameters on the characteristics of the process can be found out.
The DOE techniques used for process parameter optimization

2 Full factorial technique

3 Fractional factorial technique
4 Taguchi orthogonal array
5 Response surface method (central composite design).

3.2. Taguchi Optimization Method

Taguchi techniques are statistical methods developed by Genichi Taguchi to improve

the Quality of manufacturing goods. Basically, classical experimental design methods are to
complex and not easy to use. A large number of experiments have to be carried out when the
number of the process parameter increases. To solve this problem, the Taguchi method uses a
special design called orthogonal arrays(OA) to study the entire parameter space with only a
small number of experiments thereby reduces the overall cost and time of the experiments.

Taguchi proposed that engineering optimization of a process or product should be

carried out in a three-step approach i.e., System design, parameter design and tolerance design.
In system design the engineer applies scientific and engineering knowledge to produce a basic
functional prototype design, this design including the product design stage and process design
stage. In the product design stage, the selection of material components tentative product
parameter values, etc., are involved as to the process design stage the analysis of processing
sequences, the selection of production equipment, tentative process parameter values, etc., are
involved. Since system design is an initial functional design it may be far from optimum in
terms of quality and cost. Following on from system design is parameter design. The objective
of parameter design is to optimize the settings of the process parameter values for improving
quality characteristics and to identify the product parameter values under the optimal process
parameter values. In addition, it is expected that the optimal process parameter values obtained
from parameter design are insensitive to variation in the environmental conditions and other
noise factors. Finally, tolerance design is used to determine and analyze tolerances around the
optimal settings recommend by parameter design. Tolerance design is required if the reduced
variation obtained by the parameter design does not meet the required performance. However,
based on above discussion, parameter design is the key step in the Taguchi method to achieving
high quality without increasing cost. To obtain high cutting performance, the parameter design
proposed by Taguchi method is adopted in this project work.

3.3. Analytic Hierarchy process(AHP)

However, in the proposed work, the associate weight for each response required for
calculation of overall utility index can be obtained with the help of Analytic Hierarchy Process
(AHP). The analytic hierarchy process (AHP) is a structured technique for dealing with complex
decisions that was developed by Thomas L. Saaty in the 1980 year. It provides a comprehensive
and rational framework for structuring a decision problem, for representing and quantifying its
elements, for relating those elements to overall goals, and for evaluating alternative solutions.
The base of this model is comparing variables by pair wise by Matrix relationship. In this way,
pair wise of the effective variables on the concrete Pavement were considered and based on
relative weights the output was extent. AHP helps decision makers to find a solution that best
suits their goal and their understanding of the problem. It is a process of organizing decisions
that people are already dealing with, but trying to do in their heads. The AHP was developed by
Thomas L. Saaty in the 1970s and has been extensively studied and refined since then. It
provides a comprehensive and rational framework for structuring a decision problem, for
representing and quantifying its elements, for relating those elements to overall goals, and for
evaluating alternative solutions.

Users of the AHP first decompose their decision problem into a hierarchy of more easily
comprehended sub-problems, each of which can be analyzed independently. The elements of
the hierarchy can relate to any aspect of the decision problem tangible or intangible, carefully
measured or roughly estimated, well or poorly-understood anything at all that applies to the
decision at hand. Once the hierarchy is built, the decision makers systematically evaluate its
various elements by comparing them to one another two at a time, with respect to their impact
on an element above them in the hierarchy. In making the comparisons, the decision makers can
use concrete data about the elements, or they can use their judgments about the elements’
relative meaning and importance. It is the essence of the AHP that human judgments, and not
just the underlying information, can be used in performing the evaluations. The AHP converts
these evaluations to numerical values that can be processed and compared over the entire range
of the problem. A numerical weight or priority is derived for each element of the hierarchy,
allowing diverse and often incommensurable elements to be compared to one another in a
rational and consistent way. This capability distinguishes the AHP from other decision-making
techniques. In the final step of the process, numerical priorities are calculated for each of the
decision alternatives. These numbers represent the alternatives’ relative ability to achieve the
decision goal. Thus, they allow a straightforward consideration of the various courses of action.
Steps of AHP method are as follows:

a) Define the objective and identify the Criteria/ Alternatives.

b) A pairwise comparison matrix (A) using the fundamental scale of the Analytic Hierarchy
process Saaty has been constructed.

c) The relative normalized weight (Wj) of each criterion has been calculated by the geometric
mean method of AHP. The Geometric mean of rows in the comparison matrix can be
calculated by
1
𝑀 𝑀

𝐺𝑀𝑗 = [∏ 𝑏𝑖𝑗 ] − − − − − 𝐸𝑞. 3.1

𝑗=1

𝐺𝑀𝑗
𝑊𝑗 = 𝑀 − − − − − 𝐸𝑞. 3.2
∑𝑗=1 𝐺𝑀𝑗

d) The maximum eigen value, λmax can be calculated by the matrix product of the pairwise
comparison matrix and weight vectors and adding all elements of the resulting vector.
e) The consistency index (CI) can be determined by

(𝜆𝑚𝑎𝑥 − 𝑛)
𝐶𝐼 = − − − − − 𝐸𝑞. 3.3
𝑛−1
The smaller the value of CI, the smaller is the deviation from Consistency.

f) Consistency ratio (CR) has been calculated by

𝐶𝐼
𝐶𝑅 = − − − − − 𝐸𝑞. 3.4
𝑅𝐼
where RI is the random index value obtained by different orders of the pairwise
comparison matrices. Usually, a CR of 0.1 or less is considered as acceptable indicating
unbiased judgments made by the decision makers.

3.4. Taguchi-Utility Method

Utility can be defined as the usefulness of a product or a process in reference to the levels
of expectations to the consumers. The performance evaluation of any machining process
depends on number of output characteristic. Therefore, a combined measure is necessary to
gauge its overall performance, which must take into account the relative contribution of all the
quality characteristics. Such a composite index represents the overall utility of a
product/process. It provides a methodological framework for the evaluation of alternative
attributes made by individuals, firms and organizations. Utility refers to the satisfaction that
each attribute provides to the decision maker. Thus, utility theory assumes that any decision is
made on the basis of the utility maximization principle, according to which the best choice is
the one that provides the highest satisfaction to the decision maker.

According to the utility theory, if Xi is the measure of effectiveness of an attribute (or

quality characteristics) i and there are n attributes evaluating the outcome space, then the joint
utility function can be expressed as

𝑈(𝑋1 , 𝑋2 , … … . 𝑋𝑛 ) = 𝑓(𝑈1 (𝑋1 ), 𝑈2 (𝑋2 ) … … 𝑈𝑛 (𝑋𝑛 )) − − − − − 𝐸𝑞. 3.5

Here, Ui(Xi) is the utility of the ith attribute.

The overall utility function is the sum of individual utilities if the attributes are
independent, and is given as follows:
𝑛

𝑈(𝑋1 , 𝑋2 … … 𝑋𝑛 ) = ∑ 𝑈𝑖 (𝑋𝑖 ) − − − − − 𝐸𝑞. 3.6

𝑖=1
The overall utility function after assigning weights to the attributes can be expressed as:
𝑛

𝑈(𝑋1 , 𝑋2 … … 𝑋𝑛 ) = ∑ 𝑊𝑖 𝑈𝑖 (𝑋𝑖 ) − − − − − 𝐸𝑞. 3.7

𝑖=1
The preference number can be expressed on a logarithmic scale as follows:
𝑋𝑖
𝑝𝑖 = 𝐴 𝑋 𝑙𝑜𝑔 ( , ) − − − − − 𝐸𝑞. 3.8
𝑋𝑖
 Here, Xi is the value of any quality characteristic or attribute i, Xi' is just acceptable value
of quality characteristic or attribute i and A is a constant. The value A can be found by the
condition that if Xi = X* (where X* is the optimal or best value), then Pi = 9 Therefore,

9
𝐴= − − − − − 𝐸𝑞. 3.9
𝑋∗
𝑙𝑜𝑔 𝑋 ,
𝑖

The overall utility can be expressed as follows:

𝑈 = ∑𝑛𝑖=1 𝑊𝑖 𝑃𝑖 − − − − − 𝐸𝑞. 3.10

Subject to the condition:∑𝑛𝑖=1 𝑊𝑖 = 1 − − − − − 𝐸𝑞. 3.11

Overall utility index that has been computed treated as a single objective function for
optimization. Among various quality characteristics types, viz. Lower-the-Better (LB), Higher-
the-Better (HB), and Nominal-the-Best (NB) suggested by Taguchi, the utility function would
be higher. In the proposed approach utility values of individual responses are determined to
calculate overall utility index. Overall utility index is treated as the single objective function for
optimization.

3.5 Proposed

The following steps followed in AHP-UTILITY are given below

 Selection of process parameters and their levels.

 Conduct the experiments as per the Taguchi Design of Experiments.
 Measure the selected quality characteristics.
 Construct preference scale for each quality characteristic from realistic data.
 Assign weights to the characteristics based on Analytical Hierarchy Process (AHP).
 Determine the individual utility values and use these values as a response of selected
experimental plan.
 Find the overall utility index (U) values for the alternatives.
 Analyze the results with taguchi method.
 Determine the optimal setting of process parameters for optimum utility.
 Conduct ANOVA for finding the significance of the factors.
 Run the confirmation experiment and compare the predicted optimal values with the
actual ones.
 CHAPTER 4
EXPERIMENTAL SETUP
In the present work a medium carbon and medium tensile steel called AISI 1040 as
shown in figure 4.1 was taken as the work piece. AISI 1040 steel is suitable for the engineering
applications where higher tensile strengths are required. It is used for shafts, gears, spindles,
axles, bolts & studs, automobile parts and etc. The chemical composition and mechanical
properties of AISI 1040 steel are given in tables 4.1 and 4.2 respectively. For machining CNC
WEDM (ELECTRONICA Hitech, JOB MASTER D-ZIRE) was used. Brass wire of 0.25 mm
and distilled water are used as electrode and dielectric fluid.

Figure 4.1. AISI 1040 Steel

Table 4.1. Chemical Composition of AISI 1040

Element Composition (%) Reference Range (%)

C 0.40 0.36-0.44

Si 0.25 0.10-0.40

Mn 0.80 0.60-1.00

S 0.05 0.05

P 0.05 0.05
 Table 4.2. Mechanical Properties of AISI 1040

Property Value

Yield Strength 280 MPa

Ultimate Tensile Strength 550MPa

Elongation 1%

Rockwell Hardness 201-255

4.1. WEDM Machine Details

The experiments were carried out on a CNC WEDM (ELECTRONICA Hitech, JOB
MASTER D-ZIRE) shown in the figure 4.2. The WEDM machine has the following
specifications:
Table size : 630 mm x 470 mm

Work- tank Internal Dimensions : 800 mm x 650 mm

Main Table Travel X, Y : 400 mm x 300 mm

Auxiliary Table Travel U, V : 80 mm x 80 mm

Z-Axis Travel : 250 mm

Maximum Taper Angle : ± 30/50 Deg/mm

Job Admit : 245 mm

Max. Work Piece Weight : 300 Kg

Machining Type : Flush

Jog Speed, X, Y : 1000 mm/min

Jog Speed U, V : 500 mm/m in

Jog Speed Z : 600 mm/min

Wire Threading : SAWT

Machine Foot Print : 2350 mm x 2100 mm

Wire Diameter : 0.15 -0.3 mm

Wire Spool Size : DIN 125, DIN 160, P3R, P5R

Cutting Speed : 160 mm2/min

Best Surface Finish : 0.6 μ Ra

Figure 4.2. WEDM Setup

4.2. Range of Process Parameters

The pilot experiments were carried by varying the process parameters Flushing Pressure
(F.P) Pulse-On-Time (TON), Pulse-Off-Time (TOFF), Servo Voltage (SV), Wire Feed (WF) and
Wire Tension (WT) to study their effect on output parameters Surface Roughness (R a) and
Material Removal Rate (MRR). The ranges of these process parameters are given in Table 4.3.
From these ranges of the process parameters, different levels of process parameters (Table 4.4)
would be selected for the Taguchi experimental design and the experimental design using
MINITAB i.e. L18 OA is given in the table 4.5.
 Table 4.3. Process Parameters and Their Ranges

S.No. Parameter Range Units

1 Pulse-On-Time (TON) 115-131 µsec

2 Pulse-Off-Time (TOFF) 40-63 µsec

3 Peak Current (IP) 180-230 Ampere

4 Spark Gap Voltage 10-20 Volts

5 Wire Feed (WF) 0-10 m/min

6 Wire Tension (WT) 0-5 Kg-f

7 Flushing Pressure (F.P) 3-15 Kg/cm2

Table 4.4. Process Parameters and Their Levels

Parameter Units Level-1 Level-2 Level-3

Flushing Pressure (F P) Kg/cm2 4 8 _

Pulse-On-Time (TON) µsec 115 120 125

Pulse-Off-Time (TOFF) µsec 55 58 61

Wire Feed (WF) mm/min 2 3 4

Wire Tension (WT) Kg-f 2 4 6

Servo Voltage (S V) Volts 20 25 30

 Table 4.5. L18 Orthogonal Array (OA)

FP TON TOFF WT WF SV

S.No (Kg/cm2) (µsec) (µsec) (Kg-f) (mm/min) (Volts)

1 4 115 55 2 2 20

2 4 115 58 4 3 25

3 4 115 61 6 4 30

4 4 120 55 2 3 25

5 4 120 58 4 4 30

6 4 120 61 6 2 20

7 4 125 55 4 2 30

8 4 125 58 6 3 20

9 4 125 61 2 4 25

10 8 115 55 6 4 25

11 8 115 58 2 2 30

12 8 115 61 4 3 20

13 8 120 55 4 4 20

14 8 120 58 6 2 25

15 8 120 61 2 3 30

16 8 125 55 6 3 30

17 8 125 58 2 4 20
 18 8 125 61 4 2 25

4.3. Experimentation Procedure

A plate of 150mm x 150 mm x 25 mm size of AISI 1040 STEEL is mounted on the
WEDM machine (Figure 4.2) and specimens of 20 mm x 20 mm size are cut. The following
steps were followed in the cutting operation:

 The brass wire of diameter 0.25 (figure 4.3) was made vertical with the help of verticality
block.
 The work piece of AISI 1040 was mounted and clamped on the work table.
 A reference point on the work piece was set for setting work co-ordinate system (WCS).
The programming was done with the reference to the WCS. The reference point was
defined by the ground edges of the work piece.
 Water is used as the dielectric fluid.
 The program was made for cutting operation of the work piece and a profile of 20 mm
x 20 mm square was cut.
 While performing various experiments, the following precautionary measures were
taken:
 Each set of experiments was performed at room temperature in a narrow temperature
range (range 27ºC).
 Before taking measurements of surface roughness, the work piece was cleaned with
acetone.

After machining the work pieces were tested for the roughness (Ra) using surface tester SJ-
301 as shown in figure 4.4.

Figure 4.3. WEDM Brass Wire

Figure 4.4. Measurement of Surface Roughness
 CHAPTER 5
RESULTS & DISCUSSIONS
In this chapter the experimental results of material removal rate (MRR) and surface
roughness (Ra) are analyzed using Taguchi based utility and AHP method. The focus of the
work is to identify the optimal combination of process parameters that concurrently maximizes
the material removal rate and minimizes the surface roughness concurrently.

5.1. Experimental Results

The measured results of both material removal rate and surface roughness characteristics
were tabulated in table 5.1. In the present work, in order to determine the weights of each
criterion, a pair wise comparison matrix as shown in the table 5.2 is developed using Analytical
hierarchy process (AHP). The criterion weights are obtained as W MRR = 0.25 and WRa = 0.75
respectively. The value of CR is calculated as 0.0% which is less than the allowed value of CR
(=0.1), indicating the fact that there is a good consistency in the judgments made by the decision
maker while assigning values in the pair – wise comparison matrix.

Table 5.1 Experimental Results

S.No. MRR (cm3/min) Ra (µm)

1 9.7 2.43

2 7.32 2.755

3 7.34 2.355

4 8.33 2.351

5 7.33 2.524

6 7.7 2.491

7 8.01 2.526

8 8.55 2.726

9 7 2.59

10 8.45 2.492

11 7.06 2.251

12 7.07 2.645

13 10.05 2.964

14 8.24 2.752
 15 6.69 2.433

16 9.72 2.679

17 8.48 2.768

18 7.01 2.704

Table 5.2. Pair Wise Comparison Matrix

Criteria MRR Ra

MRR 1 1/3

Ra 3 1

The experimental results of responses were explored to calculate the utility values of
individual quality attributes (also called preference number) by using the following equations 1
and 2 respectively.
PMRR = 50.9337 * log(Xi/6.69) ………Eq.5.1
PRa = -75.3138 * log(Xi/2.964) ……….Eq.5.2

The calculated individual utility values are given in the table 5.3. Now, the overall utility
index values along with the weights of the attributes can be calculated using the equation 5.3
and the values obtained and the corresponding S/N ratios (Higher-the-Better) are given in the
table 5.4.
U = PMRR * WMRR + PRa* WRa ………Eq.5.3

Table 5.3. Individual Utility Values of Responses

S.No. PMRR PRa

1 8.2179 6.4920

2 1.9907 2.3874

3 2.0511 7.5238

4 4.8489 7.5766

5 2.0170 5.2494

6 3.1070 5.6862

7 3.9830 5.2268
 8 5.4244 2.7339

9 0.9983 4.4059

10 5.1647 5.6711

11 1.1868 9.0000

12 1.2173 3.7205

13 9.0000 0

14 4.6095 2.4251

15 0 6.4544

16 8.2614 3.3063

17 5.2411 2.2293

18 1.0289 2.9975

Table 5.4. Overall Utility (U) and S/N Ratios of U

S.No. Overall Utility (U) S/N of U

1 6.9234 16.8064

2 2.2882 7.1899

3 6.1556 15.7854

4 6.8946 16.7702

5 4.4413 12.9502

6 5.0414 14.0510

7 4.9158 13.8319

8 3.4065 10.6462

9 3.554 11.0143

10 5.5445 14.8772

11 7.0467 16.9597

12 3.0947 9.8124
 13 2.25 7.0437

14 2.9712 9.4586

15 4.8408 13.6983

16 4.5450 13.1507

17 2.9822 9.4907

18 2.5053 7.9772

The values of the overall utility are analyzed using taguchi’s Higher-the-Better
characteristic and the signal to noise (S/N) ratios were calculated. From the mean values of
process parameters given in the table 5.5, the main effect plot has been plotted to identify the
optimal combination of process parameters on the multi response. From the main effect plot for
mean values of overall utility are shown in figure 5.1. The optimal combination of cutting
parameters is obtained at FP:4kg/cm2; TON:115 μs; TOFF: 55 μs; WF: 2 mm/min; WT : 2 kg–f
and SV: 30 V respectively.

Table 5.5. Mean Values of Overall Utility Values

Level FP TON TOFF WT WF SV

1 4.847 5.176 5.179 5.374 4.901 3.950

2 3.976 4.407 3.856 3.249 4.178 3.960

3 3.651 4.199 4.611 4.155 5.324

Delta 0.871 1.524 1.323 2.124 0.746 1.375

Rank 5 2 4 1 6 3
 Figure 5.1. Main Effect Plot for Means of Overall Utility (U)

5.2. ANOVA Results

The Analysis of variance is used to investigate the significance of cutting parameters on
the performance characteristic. This is accomplished by separating the total variability of the
overall utility, which is measured by the sum of squared deviations from the total mean of the
overall utility, into contributions by each parameter and the error. The percentage contribution
by each factor to the total sum of the squared deviations SST can be used to evaluate the
importance of the cutting parameter change on the performance characteristic. In addition, the
F-test can also be used to determine which factor has a significant effect on the performance
characteristic. Usually, the change of a determined factor has a significant effect on the
performance characteristic when the F value is large. From the results of table 5.6, it is clear
that the Wire Tension is the most influencing parameter for the overall utility value.

Table 5.6. ANOVA Results

Source DF Adj SS Adj MS F-value P

FP 1 3.415 3.4151 3.79 0.100

TON 2 6.968 3.4842 3.86 0.084

TOFF 2 5.657 2.8283 3.14 0.117

WT 2 13.898 6.9488 7.70 0.022

WF 2 2.158 1.0789 1.20 0.365

 SV 2 7.503 3.7514 4.16 0.074

Error 6 5.412 0.9020

Total 17 45.010

S = 0.949742, R2 = 87.98%, R2 (adj) = 65.93%

From the residual plots of figure 5.2, it is observed that all the errors are following the
normal distribution as all the residuals are laying near to the straight line in the normal
probability plot. Versus fits and order plots are implying that the errors are distributed on both
the sides of mean line i.e. they are not following any regular pattern hence maintaining the
constant variance.

Figure 5.2 Residual Plots for Overall Utility

 CHAPTER 6
CONCLUSIONS
The present work discussed an application of taguchi based Utility method and AHP for
investigating the effects of Wire EDM parameters on material removal rate and surface
roughness in Machining of AISI 1040 steel. From the results of Utility analysis and ANOVA
the following conclusions can be drawn:

 From the Utility analysis, the optimal combination of machining parameters is obtained at
Flushing Pressure (FP) : Level 1 : 4 kg/cm2
Pulse -On-Time (TON) : Level 1 : 115 μs
Pulse-Off-Time(TOFF) : Level 1 : 55 μs
Wire Tension (WT) : Level 1 : 2 kg-f
Wire Feed (WF) : Level 1 : 2 mm/min
Servo Voltage (SV) : Level 3 : 30Volts
 ANOVA results concluded that the Wire Tension is the most influencing parameter on the
multi-responses.
 The errors are distributed normally and they are not following any regular patterns hence
following the assumptions normality and constant variance of ANOVA.

 The model prepared for the overall utility(Ui) is the best fit and it can be accurately used for
the prediction of multiple responses.
 CHAPTER 7

FUTURE SCOPE

Future Research Directions

Even though a high amount of work in the field of EDM was conducted, there are
challenges left which still require more research, and these are listed below.

• Optimizing Process Parameters: The EDM process has a multifarious nature due to the
complex discharge mechanisms, which hinders its optimization. Additionally, the
introduction of new materials constantly complicates the optimization of parameters.
Even in TS, many grades are introduced frequently; thus, more studies are required.
• Extending to a Wide Range of Workpiece Materials: EDM is primarily used for
conductive materials; however, the current trend is to investigate the potential of EDM
for machining non-conductive or semi-conductive materials, such as ceramics.
• Powder-Mix EDM: Powders of different materials are mixed with dielectrics to improve
the machining process. This is another area which requires further attention.
Researchers need to pay more attention to the machining of different tool steel grades in
different EDM types under dielectric fluids with different material powders. There is a
lack of studies covering this point.
• Use of Different Electrodes: Investigators can examine the performance of the EDM
process by using various electrode materials, shapes, sizes, and geometries. The use of
tubular electrodes is in the initial stages, and it requires further attention to deliver
promising results.
• Hybrid or Assisted EDM: The EDM process hybridized with some other processes
provides better results. Magnetic force-assisted EDM, laser with EDM, etc. are becoming
commonly used methods to overcome process limitations. The great improvement in the
performance revealed in the reviewed research was related to EDM with ultrasonic
action. Research trends may be directed toward the combination of these two processes.
• Electrode Cooling Methods: The electrode cooling mechanism represents another field of
research. The cryogenic cooling of electrodes provided positive results in terms of a
reduction in TWR.
• Electrical Discharge Turning (EDT) and Dry EDM: EDT is a very new concept and it
requires more research. Dry EDM is also gaining interest in the research community.
• Miniaturization: More efforts are needed to extend the limits of miniaturization in micro-
EDM. A smaller level of electric discharge energy is needed to overcome this limitation.
Furthermore, new techniques to avoid the distortion of micro-workpieces are necessary
in future research.
• Figure 7.1 shows a pictographic depiction of the future research directions.
 Figure 7.1. Future research areas in the EDM field

• The research directions can be categorized into four broad classes, which can be further
allocated into sub-groups, as shown in Figure 7.2.
Figure 7.2. Classification of research directions.
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