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Surface Integrity Analysis and Simultaneous Optimization Using Taguchi Grey Relational Analysis

Wire electric discharge machining (WEDM) is one of the most extensively used non conventional material removal process as it provides an effective solution for machining of hard materials with complex shapes. The selection of optimum combination of process parameters is a difficult task in WEDM as it is affected by large number of input parameters. From the literature, Pulse on time, peak current, servo voltage and wire tension are found to be the most influencing parameters and hence these parameters are considered in the present work. In any machining process, the surface roughness is a key factor that influences the properties of the materials such as wear resistance, corrosion resistance, fatigue life and so on. Cutting speed plays an effect on the economics of production. This paper presents an investigation on 316 L SS machined by WEDM to the study the effect of surface roughness and cutting speed. Experimentation were conducted by using full factorial design of experiment under different conditions of input parameters by using brass wire and demineralised water as dielectric fluid. Using Analysis of variance, the significance of the parameters is found and their optimal combination of parameters for surface roughness and cutting speed is obtained. In order to optimize surface roughness and cutting speed simultaneously, Taguchi based grey relational analysis is used to determine the optimal setting of process parameters for multiple machining characteristics. Surface integrity studies are also carried out on the machined surface. Scanning electron microscope is used to study the surface morphology of WEDMed surface.