Kerf Width Optimization in Wire-Cut Electrical Discharge Machine by using Taguchi Method

Today, in most of wire cut electrical discharge machine (WEDM), the suitable machining parameters are relied based on the data from machine manufacturer and the experience of operators. The situation became more difficult when involving numerous and diverse range of parameters and the lack of experience. Normally, the parameter tables given by the machine manufacturer is only for basic machining operation but not for optimum machining condition. The optimal machining parameters only can be achieved by determining significant parameters that are affecting the machining performance. In this paper, a Taguchi Method quality design and analysis of variance (ANOVA) is used to determine the optimal kerf width for material tool steel grade DF-2 for machining process with WEDM. The optimum machining parameter is obtained by using a analysis of signal-to-noise (S/N) ratio. After several experiments, it can be ascertained the significant parameter contributed to the kerf witdh are the open circuit voltage(47%), pulse duration(20%) and wire speed(15%). The average of kerf width from the three experiments was 0.255mm and from that, the error margin is only 1.53%, which satisfied our data .