Application of the analysis of

variance method to optimize the

quality parameters in wire electro
discharge machining.

A thesis submitted in partial fulfilment of the Requirements of a

Masters degree in Mechatronic engineering
Larry Khalisia Luvindi

Jomo Kenyatta University of Agriculture and Technology

Abstract

Wire EDM is an emerging technique in non-conventional machining for the manu-

facturing of very complex goods with a very high degree of precision . Wire EDM is
a very complicated mechanism requiring several process parameters. In the exper-
imental research, the optimization of EDM wire will be done out using, analysis of
variance method, as propounded by the Taguchi optimization process. The param-
eters concerned are pulse-on time, pulse-off time, peak current and servo voltage.
Conversely, cutting rate, Surface roughness, Dimensional variation and Wire Wear
Ratio are used as responses. Moreover, experimental work will be performed on a
Wire-EDM machine.
Wire electrical discharge machining process is a very complicated process, in
which time varies. The stochastic method is primarily relevant uses of this method
are in the fields of dies, molds, precision processing and contour cutting. Therefore,
any complex form can be created with a high degree of precision and surface finish
using CNC WEDM. No large input variables influence the performance of the device.
Therefore, the specification of a sufficient set of input variables for the wire electrical
discharge machining (WEDM) method relies heavily on the technical acumen and
experience of the operator.
WEDM is commonly used in the machining of conductive materials where ac-
curacy is of primary importance. The rough cutting process in the EDM wire faces
challenges since several output variables need regulation. For instance, material re-
moval rate (MRR), surface finish, which is a very difficult task. The aim of this
analysis is to show how the WEDM process parameters can be modified to achieve
improved metal removal rate, surface finish, electrode wear rate and dimensional
deviation.

2
Dedication

I would like to dedicate this work to the scientific community.

3
Declaration

I would like to declare that this is original work, that is free from plagiarism.

4
Acknowledgements

I would like to acknowledge the inspiration of my supervisors, who guided me in

accomplishing this task.

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Contents

1 Introduction 11
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.1 Problem statement . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1.2 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 Literature review 14
2.1 Literature review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Material removal . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 WEDM Cycle Benefits . . . . . . . . . . . . . . . . . . . . . . 16
2.1.3 WEDM-PROCESS Drawbacks . . . . . . . . . . . . . . . . . . 16
2.1.4 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Review of past research . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.1 Identified gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3 Methodology 20
3.1 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.1 Preparation of the samples . . . . . . . . . . . . . . . . . . . 20
3.1.2 Cutting rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.3 Surface roughness . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.4 Dimensional deviation . . . . . . . . . . . . . . . . . . . . . . 21
3.1.5 Pulse on time (Ton) . . . . . . . . . . . . . . . . . . . . . . . 21
3.1.6 Pulse off time (Toff) . . . . . . . . . . . . . . . . . . . . . . . 21
3.1.7 Peak current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.8 Servo voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.9 Duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.10 Wire tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1.11 Wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.12 Dielectric flushing pressure . . . . . . . . . . . . . . . . . . . . 23
3.1.13 Pilot experiments . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.14 Methodology for the design of the experiment . . . . . . . . . 25
3.1.15 Experimental design plan . . . . . . . . . . . . . . . . . . . . 25

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 3.1.16 Loss function . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.1.17 Signal to noise ratio . . . . . . . . . . . . . . . . . . . . . . . 27
3.2 Experimental analysis and design steps . . . . . . . . . . . . . . . . . 28
3.2.1 Data collection and experimentation . . . . . . . . . . . . . . 30

4 Conclusion 34

References 34

7
List of Tables

3.1 How data from the experiments will be tabulated(wire wear ratio and
dimensional deviation) . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 How data from the experiments will be tabulated(Cutting rate and
surface roughness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Incomplete L16 array table) . . . . . . . . . . . . . . . . . . . . . . . 29

8
List of Figures

2.1 Wire drag and tension relationship . . . . . . . . . . . . . . . . . . . 15

3.1 Flowchart of the methodology . . . . . . . . . . . . . . . . . . . . . . 33

9
List of Abbreviations

ECM Electrochemical machining

USM Ultrasonic machining

EDM Electrodischarge machining

WEDM Wire electrodischarge machining.

CNC Computer numerical control

OA Orthogonal array

ANOVA Analysis of variance

SR Surface roughness

MRR Material removal rate

RSM Response surface methodology

CV Cutting velocity

Ton Time on

Toff Time off

IP Pulse peak current

CIp op Population confidence interval

10
Chapter 1

Introduction

1.1 Background
Recent developments in the automobile sector have intensified the need for mate-
rials with improved structural reliability, reliability, and efficiency. Unfortunately,
conventional equipment is not helpful in machining such material satisfactorily. The
novel materials that are applicable are lightweight, combined with higher hardness
and durability[8]. Sometimes, their properties can give rise to significant challenges
during their machining. Therefore, non-conventional machining techniques, such as
electrochemical machining (ECM), ultrasonic machining (USM), electrical discharg-
ing (EDM) and newly discovered hybrid machining, are suitable for the machining
of difficult to handle materials[8].
WEDM is the most popular computer tool that is applicable in the handling of
such material. Wire Electric Discharge Machining (WEDM) is a process by which
a conductive surface is cut by a thin wire electrode (usually brass) that follows a
CNC-operated path[8]. WEDM produces an entirely unpredictable marking on a
surface, unlike the patterns created by milling cutters and grinding wheels. Since its
innovation in the 1960s, through the efforts of Lazarenko Brothers, the instrument
has revolutionized the die and tool making sector to a greater extent.
WEDM has adapted over time from first being used in the production of machin-
ing dies and tools, to machining new alloys including Conductive ceramics, Poly-
crystalline Diamond Compacts, Hastelloy, Carbide, Titanium, and Inconel. The
material is machinable machined regardless of its stiffness, and the only condition
is electrical conductivity. It is arguably the most exciting and versatile machine
tool developed by the automotive industry in the last fifty years and has several
advantages to deliver[8].
Machining on WEDM is achieved by first drilling a hole on or off the workpiece.
Here, electrical energy is transformed into thermal energy by a sequence of discrete

11
sparks created by a spark generator. Hence sparks are result from a sequence of fast
electrical pulses, created by the power supply of the system, and occurring at a pace
of thousands of times a second[8]. The spark induces an ionization channel under
extremely elevated pressure and heat levels, where the particles move between the
workpiece and the wire electrode, culminating in the vaporization of the scattered
parts. WEDM is a special model of the EDM strategy for the extraction of material
from a surface. The main difference between the WEDM method and the EDM
strategy is the type of the implement used[8].
The outline of the instrument in EDM replicates the product to be manufac-
tured. On the contrary, in WEDM a thin brass wire (usually 0.25 mm in diameter)
continuously works to curve the product. The wire is fed by a pair of tension rollers.
Both the workpiece and the tool are soaked in a constantly flowing dielectric fluid
(deionized water). The dielectric fluid has two purposes: a) Acting as an insulator
until the operational voltage is attained. b) Functioning as a coolant. It flushes the
debris away from the machining site, too. As there is no contact with the device
and the workpiece, the operation is free form the influence of external forces. This
substantially eliminates the need for specific fixtures to constrain the workpiece as
is the norm in traditional machining processes[8]. Additionally, the approach leaves
no residual burrs, thus reducing the need for any finishing step. Wire EDM often
gives designers greater flexibility when developing dies, and gives more authority to
management as machining is mostly done automatically. Parts possessing complex
tolerances and geometry usually do not need a technician with a variety of skills,
or multiple equipment. A significant rise in productivity occurs since machining is
unattended, thus permitting operators to engage in other fields. Most of the work-
pieces emerge of the system as finished parts, without the need for more operations.
This is a one-step process[8].

1.1.1 Problem statement

Wire electrical discharge machining is a stochastic, time varying and complex pro-
cess that was designed to generate complex shapes with an impressive degree accu-
racy and satisfactory surface finish. The process has essential applications in the
production molds and dies as well as contour cutting and precision manufacturing.
Therefore, the process is ideally tailor made for the generation of complex geome-
tries, with a high-grade surface finish and dimensional precision.
The output of an wire EDM process is influenced by numerous input variables.
Therefore, it is the obligation of the operator, who depends on his or her experience
and technological prowess to choose an ideal combination of input parameters, for
proper machining. Moreover, the regulation of performance measures such as the

12
surface finish and material removal rate remains, during rough cutting activities of
the wire EDM process, remains challenging.
Therefore, the goal of this research is to analyze process parameters, through an
experimental process, such as cutting rate, servo voltage, pulse on time and peak
current. The goal of the study will be to apply the analysis of variance method
to determine how such parameters influence response characteristics including di-
mensional deviation, electrode wear rate, surface finish and material removal rate.
Consequently, the process parameters will be adjusted to optimize the WEDM pro-
cess of mild steel.

1.1.2 Objectives
Main objective

To design an analytical study that will identify the optimal combination of process
parameters, including that will yield the optimal response characteristics for the
wire electro-discharge machining of mild steel,

Specific objectives

• To collect data on the interaction between process parameters including pulse

on and off times, peak current, servo voltage , and the resulting responses
including cutting rates, dimensional deviation , surface roughness and wire
wear ratios.

• To organize the data into an orthogonal array format.

• To conduct ANOVA analysis on the Orthogonal array data.

• Identification and classification of significant and influencial parameters.

• The selection of optimal combinations of process parameters that produce the

optimal response.

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Chapter 2

Literature review

2.1 Literature review

Wire-cutting devices are available in two, four and five-axis versions. The axes are
defined as the axis X, the axis Y, the axis U, the axis V and the axis Z as shown in
Figure rfns.
The X and U axis are parallel to each other in operation, the Y and V axes
are parallel in action, while the Z axis is perpendicular to the Y-V and the X-U
axes. The U and V axes are offset by the electrode wire vertically[12]. This offset
permits the wire cutter to create vertical machined planes on the workpiece when
the V and U axes place the top wire guide immediately above the bottom wire guide.
Tapered surfaces are processed on the workpiece using the V and U axes to offset
the upper wire guide from a location directly above the lower wire guide. This offset
is illustrated by the conical shape encircling the electrode wire[12].
Operations in the Z - axis may be manually or computer operated. This axis
is used to place the top wire guide near the top surface of the workpiece. The
placement of the top wire guide is important to ensure the correct flow of dielectric
liquid into the sparking zone and to allow the removal of the WEDM chips[12]. The
modification of the Z axis is required at any point during the sparking process when
a shift in contour happens on the upper surface of the machined workpiece. In the
event of a workpiece surface falling into the way of the top wire guide, the devices
could be destroyed in a crash[12].
The machine-tool contains the wire-feed feature. This device monitors wire-
traverse speed as it passes the sparking field. If the wire enters the area very slowly,
the flickering erodes and finally splits the cable. Conversely, passing into the flicker-
ing field so fast is inefficient[12]. Besides regulating wire-traverse velocity, the wire-
feed mechanism must maintain the electrode wire under sufficient tension to keep it
straight and taut. Otherwise, the machine servo mechanism does not work correctly,

14
 Figure 2.1: Wire drag and tension relationship

thus distorting the machined surface. Wire-traverse speed is a computer-controlled

operation using manufacturer-recommended settings. Settings include features like
the material, thickness, and metallurgy of the electrode wire. Workpiece material
and thickness can also influence wire-traverse speed[12].

2.1.1 Material removal

The WEDM process includes various techniques that facilitate substance removal
including heat radiation and conduction, rapid solidification, bubble growth and
collapse, electrical forces and phase changes. The best hypothesis to describe the
electrical discharge mechanism is a thermometric effect as illustrated below.
Material removal occurs due to melting and subsequent vaporization induced by
discrete sparks produced by a spark generator. Moreover, material extraction occurs
at the cathode and anode terminals in contact with dielectric fluid, which flows under
pressure[12]. Dielectric gas ionizes upon the attainment of a threshold voltage across
gap separating the tool electrodes. This produces an ionization pathway that lets
ions travel at high speeds to opposite charged electrodes. The discharge region
is heated to extremely high temperatures until the surface liquifies and degrades
away[12]. Local electrode temperatures will increase to a peak value that surpasses
the melting point of the work material by converting the kinetic energy of electrons
into heat energy. The peak energy density degrades much of the material from
both workpiece and wire by melting and vaporizing particles locally. The dispersed
particles (debris) are washed away by continuously running dielectric fluid. In the
WEDM method, wire movement is sluggish. It is fed in the planned direction,
thereby extracting material from the workpiece[12].

15
2.1.2 WEDM Cycle Benefits
[8]

• Metals, alloys, and carbides may be machined regardless of their, Strength,

hardness, durability, microstructure.

• WEDM can process any electrically conductive materials.

• The tool (electrode) and the workpiece are free from the effect of mechanical
forces and therefore do not need fixtures.

• Sharp corners and edges can be machined.

• It provides excellent surface texture, consistency, and repeatability.

• Hard workpieces are machinable because the deformation induced by the pro-
cess does not impact the final dimensions.

• It does not produce burrs.

• Hard die workpieces with complex shapes are easily machined accurately and
with an excellent surface finish.

• Because of the dielectric fluid, there is no overheating of the bulk material

• Small workpieces can be machined as there is little physical contact between

the tool and the material.

2.1.3 WEDM-PROCESS Drawbacks

[8]

• The rate of material removal is low, thus making the procedure only cost-
effective for hard to machine workpieces. item and re-cast layers are inherent
in the WEDM process thus lowering the quality of surfaces.

• WEDM is not ideal for non-conducting bodies.

• Fast electrode wear renders the process more expensive.

• WEDM surfaces usually have a matte-type look that requires more polishing
to produce a shiny finish.

16
2.1.4 Applications
[8]
To cut titanium, steels, graphite, carbides, zinc, and brass. The wire content
depends on the product desired. For rapid cutting, Zinc-coated brass wires are
used. Conversely, molybdenum wires are suitable for more precise applications than
molybdenum wires. The method is used as follows:

• Aerospace, semiconductor, electronics, and medical applications.

• Die and tool manufacturing.

• Cutting hard Extrusion Dies

• Cutting cams, gauges, and fixtures.

• Cutting gear wheels, dies and strippers.

• Fabricating hard electrodes.

• Manufacture of precise tooling for Micro-USM, Micro-EDM, and other micro-

machining operations.

2.2 Review of past research

Harshdeep and Ishu Monga(2015)[1],applied the Taguchi L16 Orthogonal array to
create a robust design that facilitated the machining of H11 steel. Moreover, the
design was helpful in the enhancement of input factors such as peak current, wire
tension, wire feed, pulse off and on times. Moreover, it also optimized output factors
including surface flatness, material extraction rate and the wire wear ratio. The
multi-response ratio, which is the signal to noise ratio was also used to approximate
the performance parameters that deviated from the real values.
Anand and Venkata(2019)[7],conducted an investigation concerning the opti-
mization of various parameters in the wire electro discharge machining of bronze-
alumina MMC. The goal of the study was to determine the best cutting parameters
that would contribute towards the development of the minimal surface roughness
value. Accordingly, the input parameters that were applied included the wire feed
rate, the pulse off and on times. Moreover, the cutting parameter settings were
generated through the use of the Taguchi L9 orthogonal array. Additionally, vari-
ance analysis (ANOVA) and signal to noise ratio (S/N) were applied to evaluate the
influence of the settings on the surface roughness. Moreover, the influence of specific
cutting parameters on the surface roughness was also determined. The outcomes of
the study identified a wire feed rate of 39.4

17
 Rao and Venkaiah(2015)[14],applied a form of response surface methodology
(RSM) design with a central composite face to plan their evaluation as they opti-
mized process attributes on a Nimonic- 263 alloy. The applicable input parameters
were servo voltage, peak current, pulse off and on times. Additionally, the impor-
tance of process parameters is evaluated through the application of the ANOVA
method. Moreover, they created models for forecasting the valuers of surface rough-
ness and MRR. Consequently, they determined the key of SR and MRR to be
0.363162µm and 3.59856 mm3 /min,respectively .
Likewise, the best values obtained after the application of particle swarm op-
timization algorithm, for SR and MRR were 0.2618 µm and 3.6713 mm3 /min. A
comparison of the PSO results to the RSM technique revealed that the PSO method
generated more accurate results.
Kubade et.al(2015) optimized the parametric process combinations of wire speed,
pulse off and on times by applying the Taguchi L27 orthogonal array at all three
levels on Titanium Dibromide. Signal to noise ratios of the overcut, material removal
speed and surface roughness were computed. Consequently, the variance analysis
(ANOVA ) method and response graphs were applied to analyze the outcomes[6].
Dewangan et al(2015)[3],used the electro discharge method (EDM) to machine
AISI P20 tool steel while investigating the impact of input variables on the surface
quality of the surface. The experimental setup was designed with the aid of Response
Surface Methodology (RSM). Moreover, the relevant input parameters were tool lift
and tool work times, pulse on time and discharge current. Furthermore, fuzzy logic
and grey relational analysis was applied to compute the grey fuzzy reasoning grade
(GFRG) .The main results of the evaluation indicated that the pulse on time and
discharge current were the chef determinants of the surface integrity of a workpiece.
Consequently, the optimal results found were, Tup = 0.0s, Tw= 0.2s, Ton = 10 and
IP = 1 A.
Azhiri et al(2014)[15],studied the effect of that dry WEDM machining has on
the processing of SiC/Al composite. In the experimental arrangement, a gaseous
medium substituted the liquid dielectric and its role was to improve the quality of the
processing environment. Brass wire and oxygen gas were chosen to function as the
tool electrode and gaseous medium respectively. After a sequence of tests, the two
components cut the composite at an impressive velocity. Furthermore, the test also
applied an orthogonal array to study the impact of wire feed, wire tension, discharge
current, gap voltage, pulse off and on times on the cutting velocity. Additionally,
an adaptive neuro-fuzzy inference system was modified to establish the relationship
between process responses and inputs. Finally, a grey relational analysis procedure
was implemented to optimize SR and CV simultaneously. Consequently, it was
established that discharge current and the pulse on time have notable influences on

18
SR and CV.
Rao et al(2014)[9]applied linear regression models and hybrid genetic algorithms
to enhance the material removal speed and surface roughness, during the machining
of Aluminum 2014T6. Their findings showed that spark gap, pulse on time and the
peak current significantly impact both machine removal rate and surface roughness.
Saedon et al(2014)[11]performed experiment to establish the influence of material
removal rate, cutting rate surface roughness, wire tension, wire feed, pulse off and
on time on the machining of titanium alloy. They applied a combination of grey
relational analysis and orthogonal arrays to optimize response parameters. The
best machining settings included a wire feed of 4mm/min, wire tension of 16N, peak
current of 12A and pulse off time of 3us.
Equbal et al.(2014)[4],applied grey relational analysis to improve the process fac-
tors during the forging spring saddle. Input parameters such as friction coefficient,
die temperature, billet temperature, flash thickness and their interactions were in-
vestigated with L27 OA. Analysis of variance was also helpful in the evaluation of
important parameters.

2.2.1 Identified gaps

After a thorough literature study, some research gaps emerge in studies concerning
the WEDM machining.

• Researchers have not comprehensively identified the process parameters that

influence the performance metrics of WEDM machining have not been.

• The literature review proves that have mainly focused on control, monitoring
and WEDM developments but negligible studies have been performed on the
optimization of operational variables.

• The multi-response WEDM process optimization has been largely ignored by

previous researchers.

• The influence of machining factors on the processing of Incoloy-800 has not

been properly studied with WEDM that applies a brass electrode.

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Chapter 3

Methodology

3.1 Methodology
A material of dimensions 10 cm * 10cm * 1 cm will be utilized as the work piece of
mild steel.

3.1.1 Preparation of the samples

Preparation of the samples Rectangular samples of 10 * 5 * 5 mm will be extracted
from a work piece using a brass wire electrode with a diameter of 0.25 mm. Mea-
surement of important parameters.

3.1.2 Cutting rate

In the WEDM process, the cutting rate is an essential parameter, and it should be
elevated to promote the efficiency of the equipment while economically machining
the work piece. Moreover, the cutting rate gives information concerning the material
removal rate (MRR), which contributes towards the computation of the efficiency
of the equipment. In this research, we will compute the cutting rate in mm/min,
and the period in which a specimen is cut will be measured by a stopwatch[13].

3.1.3 Surface roughness

The surface roughness can forecast the future qualities of a mechanical component
since as surface irregularities usually initiate the development of nucleation sites that
result in corrosion or cracks. Additionally, the surface roughness is a function of
factors such as deformation, friction, accuracy and the tape of contact. To quantify
surface roughness, one should measure how the actual surface deviates form its
ideal horizontal form. Accordingly, larger deviations will correspond to a rougher
surface while smaller deviations correspond to smother surfaces. Moreover, the

20
roughness can be assumed to be a short wavelength and high frequency constituent
of a measured plane, which is described by the Ra value[13]. To measure the mean
roughness of a surface, we compare all the valleys and peaks of the plane to an
average line, before computing an average value for the whole cut-off distance. The
cut-off length is simply the length through which a stylus is dragged along a surface.
Therefore, a longer length provides a more mean value while a shorter length will
provide an inaccurate result, if utilized on a shorter length of a surface.

3.1.4 Dimensional deviation

In the WEDM machining the job profile differs from the wire profile. Therefore,
the actual product of the WEDM process might be oversized or undersized. The
cross section of the specimen should be measured by means of a digital micrometer
with the least count of 0.01mm. Next, the dimensional deviation can be computed
in a percentage format by applying the following expression[13]. Dimensional Devi-
ation = (Recorded value – Actual value / Actual value)* 100 Choosing the process
parameters To choose the process parameters which might impact the machining
properties of WEDM machined components, can rely on the Ishakawa cause and
outcome diagram, that is illustrated below.

3.1.5 Pulse on time (Ton)

Electric discharge processing must commence at an instance described as on time
and conclude at the off time, in a alternating fashion during machining. The pulse
on time is the span in microseconds in which electrical discharge is emitted between
an electrode wire and the workpiece[13]. Accordingly, the current moves only in
this instance of the cycle during the application of voltage between the electrodes.
TRo obtain a long discharge, a greater value of ON time must be chosen, which is
expressed as Ton. Furthermore, the discharge energy rises as the Ton period also
increases, thus increasing the cutting rate. A greater discharge value might instigate
a short circuit that will disintegrate the wire. However, the surface profile suffers
damage at elevated levels of pulse on time[13].

3.1.6 Pulse off time (Toff )

The pulse off time is measured in microseconds, and is the period in which an electric
discharge does not happen, since no voltage is introduced between an electrode and
a workpiece[13]. Accordingly, it is the period between the emergence of a series of
sparks, and is expressed as Toff. Whenever the values of Toff are low the quantity of
discharges occurring at a time interval rises thus improving the sparking efficiency.

21
Consequently, the cutting rate also rises. Moreover, lower discharge values might
instigate wire breakage thus lowering the cutting efficiency.

3.1.7 Peak current

This is the peak level of current which flows across the circuit in the pulse on time
phase and is measured in terms of amperage. Moreover, it is an indicator of the
amount of power consumed by the WEDM process. Accordingly, a greater value of
current is sufficient for roughing in cavities, roughing work or for workpieces with
expansive surface areas. Moreover, a rise in peak current also influences a rise in
the cutting rate[13].

3.1.8 Servo voltage

The servo voltage usually regulates the retraction and advancement of the wire. As
the machining process proceeds, the average machining voltage will change accord-
ing to the machining state between the electrode and the workpiece. Accordingly,
whenever the average machining voltage surpasses a predefined voltage level, the
wire moves forward. Conversely, a lower average voltage will induce the opposite
effect of wire retraction. The work table retracts or advances while the wire retains
its original position. Therefore, an increase in servo voltage increases the space be-
tween the workpiece and the electrode thus reducing instances of electric sparks, and
reducing the machining rate. In juxtaposition, a lower servo voltage is associated
with a smaller gap, causing more instances of electric sparks and high cutting or
machining rates. Instability in the configuration of the machining gap might cause
wire breakage[13].

3.1.9 Duty cycle

The duty cycle is the amperes ulitized in a wire EDM machining operation, and
is the ratio of the pulse-on time to the sum of pulse off and pulse on times during
a cycle[13]. Duty cycle = Pulse on time/ Pulse off tile + Pulse on time Upon
calculation of a duty cycle, the mean machining amperes can be computed as: IA
= IP * Duty cycle IP = Peak amperes. IA= Average amperes.

3.1.10 Wire tension

The wire tension is related to the straightness level of an electrode wire. This implies
that the wire will remain straight whenever its tension is high and it will assume
a bent disposition if it possesses low tension. Accordingly, it is the load in grams
that a perpetually fed wire is subjected to maintain its straightness between its

22
guides. As the wire is continually fed during the machining operation, adequate
wire tension ensures that it does not deflect excessively from its ideal path. The
deflection might result from the dielectric pressure and reaction forces due to the
induced sparks. Therefore, inadequate tension might impact the accuracy of the
process and contribute towards wire breakage[3].

3.1.11 Wire feed

The wire feed is instrumental in computing the precise speed of feeding the wire
through guides. A higher feed implies that more wire will be needed in the process
thus increasing the expenditure resulting from the machining process. Conversely,
lower speeds might cause wire breakage if cutting occurs at elevated speeds[4].

3.1.12 Dielectric flushing pressure

This is an essential factor in the WEDM process. The pressure of a machine is either
low (0) or high (1), and the dielectric fluid should possess high input pressure to
cut across thicker geometries with greater levels of pulse power. On the other hand,
lower input pressures are suitable for trim cuts and thin workpieces[13]. The most
typical dielectric liquid in the WEDM process is deionized water since it is does not
pollute the environment. Even though electro discharge can be performed in the air,
it is unstable and is not applicable in rough cut machining operations. Therefore, the
presence of dielectric fluid is a necessary precondition for the generation of a stable
electric discharge. Proper chip extraction and cooling can stabilize electric discharge
in the dielectric liquid. However, a high speed gas jet would flush debris more
efficiently from the discharge gap thus bettering the surface finish, and improving
the stability of the process[13].

3.1.13 Pilot experiments

The aim of conducting a pilot experiment is to examine how certain process param-
eters of the WEDM process vary with performance qualities such as dimensional
deviation, wire wear ratio, surface roughness and the cutting rate. Accordingly in
the pilot experiment phase, various input factors are altered including peak current
(IP), servo voltage, pulse off time (Toff) and pulse on time (Ton). Moreover, the
impact of these input factors are observed on the dimensional deviation, wire wear
ratio, surface roughness and the cutting rate. In addition to the aforementioned
parameters, other parameters which will remain constant at a predetermined value
in the experimental phase include :

23
 Experiment number Ton Toff IP(A) Ww ratio SV Dimensional deviation S/N ratio
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Table 3.1: How data from the experiments will be tabulated(wire wear ratio and
dimensional deviation)

Experiment number Ton Toff IP(A) C rate SV SR S/N ratio

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Table 3.2: How data from the experiments will be tabulated(Cutting rate and surface
roughness)

24
3.1.14 Methodology for the design of the experiment
Orthogonal array

In this process, the quality of a process is calculated by the variance of the charac-
teristics, from the ideal goal value[5]. From this deviation, a loss function is created.
These variations are caused by unforeseeable causes and are also known as noise
factors. The orthogonal array approach aims to mitigate the effects of noise, since
the removal of noise sources is impractical. Instead of checking all possible combi-
nations, such as the complete factorial design, the Taguchi system checks selective
pairs of combinations[5]. This helps the researcher obtain the requisite data, and to
determine which variables have the greatest effect on product quality with a minimal
amount of experimentation, saving time and energy. The Taguchi approach is best
used where there is an intermediate number of variables (3 to 50), few correlations
between variables, and only a few parameters contribute significantly. The arrays
are chosen based on the number of parameters (input variables) and the number of
stages (states). Examination of the variance of the data obtained from the Taguchi
configuration of the tests may be used to pick new parameter values to improve the
output characteristics. Data from the arrays can be studied by plotting the data
and running the ANOVA test[5]. In this research effort, orthogonal arrays will be
applied to strategize the experimental phase and analyze the resulting data.

3.1.15 Experimental design plan

The orthogonal array approach will be applied in the organization of the experi-
ment. We can describe these orthogonal arrays as generalized Graeco-latin cubes:
Therefore, an experiment is designed through the selection of the best OA (orthogo-
nal array) and the subsequent assignment of important interactions and parameters
to the relevant columns[5]. Additionally, the application of triangular tables and
linear graphs will simplify the process of assigning parameters. In this approach,
the outcomes of the trials will be evaluated to realize the some or all the following
listed objectives:

• To approximate the response assuming that the conditions are optimal.

• To approximate the role of individual interactions and parameters.

• discover the optimum condition of a process or a product.

The optimum condition will be specified after observing the major impact of
each parameter. Accordingly, the main effects illustrate how each parameter in-
fluences the process. Accordingly, by understanding how various parameters affect
the process, one can recommend the control approach that will be relevant for the

25
production process[4]. Consequently, the analysis of variance method(ANOVA) has
emerged as the best statistical method that is applicable to the outcomes of tests to
determine the amount of contribution of every parameter, that is measured against
a predefined degree of confidence. The ANOVA table for a particular analysis aids
in identifying the key parameters to be manipulated[4].
According to [5], there exist two distinct methods that can be applied to per-
form a comprehensive experimental analysis. In the first conventional method the
outcomes of the mean of repetitive runs or a single run is processed via ANOVA
analysis and main effect. This is also referred to as the raw data analysis.
In the second analysis, which is endorsed by [6], involves multiple runs and the
application of the signal to noise ratio or S/N ration for similar steps in a study. The
S/N ratio is a metric that evaluates the concurrent quality and is related to a loss
function. Accordingly, through the maximization of the ratio, the associated loss
diminishes. Therefore the ratio will highlight the most robust group of operating
factors according to the variation exhibited by the results. Moreover, the S/N ratio
is considered to be a response or raw data transform of an experiment. [5] favours
the application of the outer OA to intentionally introduce a variation of noise in the
experimental setup. In practice however, the process is subjected to numerous noise
factors, whose combined effect strongly impacts response variation.
For highly noisy scenarios, it is irrelevant to detect individual noise factors and to
apply control measures to curtail their effect in the experimental process. Conversely
it is enough to produce repetitions at every experimental stage of controllable factors
and to perform an effective analysis with an effective S/N ratio[5].

3.1.16 Loss function

The quality of a finished product is the property that prevents loss to the consumer
at the instance the product is shipped. It should be quantified in monetary values,
and is linked to a measurable properties of the product. The orthogonal array
method defines the loss of product quality with the aid of a “loss function.” The
method relates a functional description with a monetary loss by appling a quadratic
function, which is parabolic in form. Therefore, the loss function is the quantity
that is related or proportional to the amount of deviation from an ideal or nominal
quality property. Accordingly,[5] highlights the quadratic equation below to be a
practical function.
L (y) = K (y − m)2 Whereby:

• M = Characteristic is defined at this value.

• L = The monetary loss.

26
 • Y = the real value of the property

• K = A constant that depends on the monetary unit in question and the size
the characteristic.

This loss function is illustrated in graph below, and its qualities are: The loss
increases with a rise in the variation of the characteristic of the product from an
ideal value. Accordingly, the loss should be null whenever the quality property of a
product attains a target value. It is not a sudden step but is a continuous function .
The consequence of its continuous nature shows that just manufacturing a product
withing specified quality limits does not imply that it is of a desirable quality.

3.1.17 Signal to noise ratio

The signal to noise ratio is a logarithmic function of the ideal output. Moreover, it
is the ratio of the mean to the standard deviation. In this case, the mean implies
the signal while the standard deviation refers to the prevailing noise. Additionally,
this ratio is a function of the quality parameters of the process of product that
is to undergo optimization. A greater signal to noise ratio means that the signal
exceeds the random effects resulting from the noise factors. Accordingly, the process
operation characterized by the peak signal to noise ratio will lead to the best quality
with lower variation[3]. The signal to noise ratio combines a series of repetitions into
a single value, and a pair of data points will be sufficient for the operation to be
successful. There are different equations that compute the S/N ratios for nominal
is best (NB), larger is better (LB) and smaller is better (SB) scenarios[8].

• Larger is better
S


N HB
= −10 log10 (M SDHB ) dB
Whereby: M SDHB = n1 ni=1 Y12
P
i

– MSD = mean squared deviation

– Yi = The response of an ith experiment.
– n = the number of replication.

• The smaller the better NS LB = −10 log10 (M SDLB ) dB

Whereby: M SDHB = n1
Pn 2
i=1 (Yi )

• Nominal is the best NS LB = −10 log10 (M SDLB ) dB

2
Whereby: M SDHB = n1
P n
i=1 (Yi − Yo ) Yo = Target response value.

As illustrated in the figure 3.1, the important steps are as outlined below.

27
3.2 Experimental analysis and design steps
Choice of the orthogonal array

Before selecting an appropriate orthogonal array, one has to consider the following
preconditions[1].

• Experimental analysis and design steps

• The number of levels required by the process parameters.

This research effort involves four process parameters, therefore four levels.The choice
of the parameters to study depends on the process or product performance qualities
or important responses. According to the Taguchi design philosophy[11], a group
of four levels on every parameter will have three degrees of freedom. Therefore,
this study will have 12 degrees of freedom for all the process parameters. The
recommended, four level orthogonal array that befits this study is the L16 array,
containing 15 degrees of freedom.An uncompleted table that will be filled with the
aid of triangular tables and linear graphs is as shown below[11]. Note:

• A = Time on

• B = Time off

• C = Servo voltage

• D = Peak current.

There are various ways of defining the parameters that should be part of an ex-
periment, and they include cause-effect diagrams, flow charting and brainstorming.
An experiment typically has a number of degrees of freedom. The sum of these
degrees of freedom depends on the quantity of trials[3]. Accordingly, the degree of
freedom of a parameter will rise of decline with a commensurate rise of decline of the
levels of the parameter. This phenomenon results from the relationship between the
levels and the degrees of freedom, whereby the degrees of freedom that a parameter
has is less than the level of the particular parameter by one[5]. Increasing the total
level of a parameter will cause a rise of degrees of freedom of the experiment and the
number of trials needed. Therefore, to reduce a magnitude of an experiment, it is
recommended to select two levels per parameter. In case a higher order polynormal
or curved interaction between the parameters under investigation and the response
suspected to exist, then three levels per parameter would suffice[5]. The typical two
and three levels are:

• Two levels include L4, L8, L16 and L32.

28
 Experiment number A B C D
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Table 3.3: Incomplete L16 array table)

• Three levels include L9, L18 and L27.

The numbers indicate the number of trials that would be sufficient for the array,
while the sum of the degrees of freedom is equal to the aforementioned number less 1.
Whenever any orthogonal array is chosen for a trial the following inequality should
be apparent[14]. F greater or equal to the sum of degree of freedom needed for the
interactions and parameters. A suitable OA will be chosen depending on the total
degrees of freedom and parameters needed for the experimental procedure.

Parameter assignment

There are multiple columns available for assigning parameters and several columns
to the OA.The consequence of the relationships of these variables will then be calcu-
lated[6]. Taguchi has issued two Resources for assisting the assigning of parameters
and relationships to arrays (Ross, 1988; Roy, 1990):

• Vector graphics

• Triangular tables

Each OA has a specific set of linear graphs and a triangular table paired with
it. Linear graphs show the different columns to which variables can be allocated,
and the columns then determine the relationship of these variables. All potential
relations between parameters (columns) are included in the triangular tables. The
variables and relationships are allocated to the OA columns using the triangular
tables or linear graphs of the chosen OA[5].

29
3.2.1 Data collection and experimentation
The experiment will be conducted against any of the constraints of the inner array.
A test condition experiment is replicated either simply (if the outer array unused) or
according to the outer array (if utilized). Randomization should be done to minimize
bias in the experiment. The data (raw data) are reported against each test condition
and the S/N ratio of the replicated data points.They shall be measured and reported
against each trial condition.

Parameter design plan

When ANOVA analysis is done on raw data (detects control variables that affect
average) and S/N data (recognizes control variables that influence variation) are
done, the controlled variables can be divided into four groups[2]:

• Class I: parameters that influence both the average and the variance.

• Class II: parameters that only influence the variance.

• Class III: Parameters that only influence the average.

• Category IV: parameters that do not impact anything. (Not important for
both ANOVAs)

The modeling technique of the parameters involves picking the right class I and class
II parameters to minimize variance and class III parameters to change the mean to
the goal value. Class IV criteria can be specified most economical values, because
nothing is impacted[2].

Selection of optimal values

As previously mentioned, the impact of the process parameters including pulse off
time, pulse on time , servo voltage and peak current, on the quality parameters
such as surface roughness and the cutting rate will be studied, by ANOVA analysis.
Consequently, the optimal combinations of the process parameters will be selected
from plots and the resulting data tables to compute the best surface roughness and
cutting rates. It is noteworthy that a higher cutting rate is desirable hence the levels
of parameters, which are the servo voltage, peak current, pulse off time and pulse
on time, chosen should contribute towards increasing the cutting rate. Conversely,
the surface roughness, dimensional deviation and wire wear ratios should minimize
the therefore, the combination of valuers for servo voltage, peak current, pulse off
time and pulse on times should provide the minimum value of surface roughness.
Moreover, data analysis of the signal to noise ratio (S/N) will suggest the parameter
settings to be considered for all three cases.

30
Estimating the best quality or response characteristics

Y0 = Ai + Bi + Ci + Di − 3T [10]
Whereby:

• Ai =Average response parameter value at a level of pulse on time.

• Bi =Average response parameter value at a level of pulse off time.

• Ci =Average response parameter value at a level of peak current.

• Di =Average response parameter value at a level of servo voltage.

• Ti = Overall mean response value

• Y0 = Optimal response value.

Forecasting of the mean

Once the optimum state has been determined, the mean response at the optimum
condition is estimated. The mean is calculated only on the basis of important factors.
The related parameters are defined by the ANOVA. Suppose that parameters A and
B are important and that A2B2 (second level A, second level B) is the optimum
state . The average at the optimal state (optimal response value) is calculated as:
u = T + (A2 − T ) + (B2 − T )
Whereby:

• T = The overall response mean.

• A2 and B2 are the mean response values at the second levels of the respective
parameter A and B.

[4]

Calculating the confidence interval

An estimation of the mean(u) is only useful if we consider the average of the out-
comes from an experimental process. In statistical terms, the mean gives a fifty
percent of the actual average exceeding the u. Therefore, it is important to de-
scribe the values of a statistical variable as a range it might be included in, for a
particular confidence level. The range is known as the confidence level and is the
minimum and maximum value interval, in which the real average should be at a
predefined confidence percentage. The following two forms of confidence are recom-
mended by Taguchi, as being ideal for the approximated mean of the best treatment
condition[2].

31
 • Around the approximate mean of the treatment condition that was forecasted
during the experiment. This form of confidence interval is labelled as CIp op,
an abbreviation of population confidence interval.

• Around the approximated mean of the treatment condition applied in a con-

firmation practical to validate the predictions. The form of confidence interval
is labelled as CIce or the confidence interval of the sample group.
q
CIpop = F α(n, f e) × ( NVee )
Whereby:

• Ve = Error variance

• n = factor of the degree of freedom

• fe = error term degree of freedom.

• Nef f = effective replications.

Nef f =Total of the results / Degree of freedom mean+ Degree of freedom of all the
parameters that are useful in estimating the average performance

32
Selection of an orthogonal array by choosing parameters, levels, interactions and degrees of freedom

Assigning interactions and parameters to columns of the OA

Choose repetitions Noise? Consider the noise factors

Run experiments,record data, compute S/N ratio

Conduct ANOVA analysis on S/N and Raw data

Identify control variables affecting variance and mean, in the case of RaW and S/N data

Classify the factors according to their significance from class I to IV

Reduction of variance and adjustment of mean, and choice of economical class IV factors

Specify optimal range, confidence level and predict the mean

Draw conclusions

Figure 3.1: Flowchart of the methodology

33
Chapter 4

Conclusion

In conclusion, wire EDM is a non-conventional machining technique that can pro-

duce highly very complex geometries with a very high level of precision. Moreover,
wire EDM is a very complicated mechanism requiring multiple process parameters.
The goal of this study is to apply the ANOVA method to optimize and define the
best parameters for high quality Wire EDM machining. The parameters under study
are the pulse-on time, pulse-off time, peak current and servo voltage. On the other
hand, the cutting rate, surface roughness, dimensional variation and wire wear ratio
will serve as the responses, and the experimental study will be done of a suitable
wire EDM machine. Accordingly, at the end of this research process, we should
define the optimal set of variables for the various performance measures with the
aid of the analysis of variance method and the important process parameters.

34
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