The Effects of Wire Electro Discharge Machining (WEDM) on Machining of AISI D2 Tool Steel

The paper presents a systematic examination of the material removal rate and surface roughness, considering variations in input power, pulse frequency, pulse-on time, and servo voltage. Each of these parameters is systematically varied within an experimental matrix designed using the Taguchi L27 orthogonal array. For each experimental trial, a specimen measuring 20×10×2 mm is extracted from a rectangular block. The Taguchi utility-based approach and Analysis of Variance serve as the analytical tools applied to scrutinize and interpret the experimental results. The findings of the analysis revealed that among the considered process parameters, input power, and pulse frequency exert the most significant influence on material removal rate. Additionally, the investigation highlights that input power and pulse-on-time play pivotal roles as the most influential factors affecting surface roughness. This study contributes valuable insights into the intricate relationship between WEDM process parameters and the machining performance of D2 tool steel. The results not only facilitate a nuanced understanding of the key factors impacting material removal rate and surface roughness but also pave the way for informed parametric optimization strategies, in the pursuit of enhanced machining outcomes.