Investigation of the effect of process parameters on material removal rate in machining of is 5986 fe 410 steel by wire-EDM: The optimization and regression modeling

Non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters, namely current (I_c), pulse-on time (T_on), pulse-off time (T_off), wire-speed (W_s) and voltage (I_v) on material removal rate (MRR) is investigated while machining of IS 5986 FE 410 steel by wire-electrical discharge machine (wire - EDM). The experiments were designed using Taguchi L₁₆ arrays and results are analysed using statistical methods. The process parameters such as T_off, I_c and W_s showed significantly the contribution by 54.17%, 22.08% and 13.77%, respectively, on MRR. Further, the process parameters were optimized obtaining higher MRR which yielded 1.23 mg/s at settings I_c -5A, t_off-40 µs, T_off-5 µs, W_s - 1400 rpm and I_v - 90 V. Regression model is developed to predict the MRR with the control parameters with _₂ values 89.30%. The model predicting accuracy of the model is verified by the confirmation experiments.