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Optimization of Correlated Quality Characteristics in WEDM Process using Taguchi Approach Coupled with Principal Component Analysis

Abstract In the present work, an attempt has been made to solve the correlated multi-response optimization problem of wire electrical discharge machining (WEDM) of EN-31 steel. The experimental investigation have been carried out to evaluate the best process environment which could simultaneously satisfy multiple quality characteristics such as material removal rate (MRR), surface roughness (Ra) and dimensional deviation (DD). In view of the fact that traditional Taguchi method cannot solve a multi response optimization problem, weighted principal component analysis (WPCA) has been coupled with Taguchi method to overcome this limitation. The multiple responses are converted into a single response using principal component analysis so that influence of correlation among the responses can be eliminated. Values of individual principal components multiplied by their priority weight were added to calculate the composite principal component defined as multi-response performance index (MPI). MPI is used as response for optimization using Taguchi's L27 orthogonal array. From analysis of variance, pulse on time was found to be the most significant parameter. Finally, the optimal result obtained was verified through confirmatory test.