MULTI-RESPONSE OPTIMIZATION OF CNC WEDM PROCESS

PARAMETERS FOR MACHINING INCONEL 718 USING TAGUCHI

GREY RELATIONAL ANALYSIS (TGRA)
1
B. SATYANARAYANA, 2G. SRIKAR
1
Associate Professor, Department of mechanical Engineering, VNR VJIET, HYDERABAD-80,
2
Student, Department of mechanical Engineering, VNR VJIET, HYDERABAD-80,

Abstract- WEDM process is extensively used in the machining of conductive materials when the prime importance of the
operation is precision. This paper presents the investigation of material removal rate, kerf width, and wire wear ratio of
WEDM process on INCONEL 718. Using Taguchis parameter design, significant machining parameters affecting the
performance measures are identified as pulse off-time, pulse on-time, water flowrate, wire feed, and wire tension. The effect
of each parameter is studied individually using the plots of signal to noise ratio.

Keywords- Grey Relational Analysis, Process parameters, S/N ratio, Taguchi method, and WEDM.

I. INTRODUCTION discharge like a band saw by moving either the

Electrical Discharge Machining (EDM) is an
unconventional, thermoelectric material removal
process whose principle is to generate a series of high
frequency, discrete sparks between a work electrode
and tool electrode immersed in a liquid dielectric
medium. These electric discharges melt and vaporize
the work material, which are then flushed away by
the dielectric liquid. The dielectric acts as a de-
ionizing medium between the two electrodes and is
used to flush out the material debris from the
machining gap allowing for optimal spark generation.
The wire cut EDM uses a very thin wire as an
electrode machines the workpiece with electrical
workpiece or wire.
This allows for machining of complex and intricate
cutouts without using a forming electrode. WEDM
equipment consists of a workpiece electrode, tool
electrode, a control to accurately move the wire along
the workpiece, and a dielectric medium (usually de-
ionized water) to ensure the spark only applies energy
in the small gap between the wire and the workpiece.
The dielectric medium prevents heat build-up in the
work material which would affect the size and
positional accuracy of the machining operation. Wire
EDM is primarily used for high-precision machining
of conductive metals, metallic alloys, graphite,
nimonics and even some ceramic materials.

Fig.1 Schematic showing working principle of WEDM

II. LITERATURE REVIEW Each of the above factors has been studied
individually using plots of signal to noise ratio. They
Ricky Agarwal has found the important parameters to concluded that in order to optimize all three
be pulse peak current, pulse on time, and duty factor. objectives i.e. MRR, EWR and surface roughness

Proceedings of 09th IRF International Conference, 27th July-2014, Bengaluru, India, ISBN: 978-93-84209-40-7
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Multi-Response Optimization of CNC WEDM Process Parameters for Machining INCONEL 718 using Taguchi Grey Relational Analysis
(TGRA)
simultaneously, mathematical models using the
nonlinear regression model have to be developed.
Mohd Syafiq Bin Dzulkapli has studied the effects of
WEDM parameters on surface roughness for
machining, die-steel using parameters, voltage open,
pulse-off time and pulse peak current and have
concluded that the surface roughness of specimen
increases when pulse-peak current increase.
J. T. Huang, Y. S. Liao studied the optimization of
WEDM based on Grey relational and statistical
analysis. They conclude the following:
1. Feed rate and pulse-on time in MRR and pulse-
on time has significant influence on gap width and
surface roughness.
2. Using Grey relational analysis can be applied
extensively to cases where performance is determined
by many parameters at multiple quality requests.
Manoj Kumar Mahonta has optimized the micro-
WEDM by analysing different process parameters
(voltage, current, and pulse on time) on temperature
distribution of aluminum workpiece by comparing the
same parameters with INCONEL 718.
Goswami, J. Kumar have investigated the surface
integrity, material removal rate and wire wear ratio
for WEDM of Nimonic 80A alloy using GRA and
Taguchi method and have found pulse-on time and
pulse-off time to be the most significant factors
influencing MRR.
H. Singh, R. Garg have studied the effect of various
process parameters and their effect on the material
removal rate of hot die steel (H-11) using one
variable at a time approach and conclude that:
1. Wire feed and wire tension has no effect on
MRR.
2. MRR directly increases with increase in
pulse on-time and peak current.
3. MRR decreases with increase in pulse off-
time and servo voltage.
S. Sivakiran, C. Bhaskar Reddy, C. Eswara Reddy
present an attempt to study the influence of various
machining parameters of WEDM and have developed
a relationship between control parameters and output
parameter (MRR) by means of linear regression on
EN-31 tool steel and found the order strength of
parameters as current, pulse on time, bed speed and
pulse off time.
S. V. Subrahmanyam, M. M. M. Sarcar demonstrate
the optimization of WEDM process parameters for
machining of H13 HOT DIE STEEL with multiple
responses, material removal rate (MMR) surface
roughness (Ra) and conclude that Grey based
Taguchi method is most ideal and suitable for
parametric optimization of wire-cut EDM process
when using multiple performance characteristics.
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94
Resit Unal, Edwin B. Dean presents an overview of
Taguchi method and also briefly explains the
involved steps. They conclude the principal benefits
to be considerable time and resource savings;
determination of important factors affecting
operation, performance and cost; and quantitative
recommendations for design parameters which
achieve lowest cost, high quality solutions.
III. MINITAB
MINITAB is a powerful statistical software package
used in the areas of mathematics, statistics,
economics, sports and engineering. It is highly
interactive software which makes entering data,
conducting regression analysis, ANOVA analysis,
designing experiments using DOE, performing
Taguchi analysis, drawing control charts for
processes, performing reliability/survival tests,
multivariate tests, plotting time series plots, etc. very
easy and time saving. It is the best tool for data driven
quality improvement programs. In this project,
MINITAB (version 17) has been used for ANOVA
analysis and for plotting various graphs.
Table I Machining parameters and their levels
IV. PROCESS PARAMETERS
Experiments were performed to study the process
variable at different setting of pulse-on time, pulse-
off time, water flowrate, wire feed, and wire tension
on a WEDM machine with the following process
parameters.
Table II Process parameters
S.NO Parameters Range
1 Pulse On time 120-130s
2 Pulse Off time 50-60s
3 IP 230V
4 VP 2V
5 Water flowrate 5-15lit/min
6 Wire Feed 1-3m/min
7 Wire Tension 7-9g
8 Servo Voltage 20
9 Dielectric fluid De-ionized water
 Multi-Response Optimization of CNC WEDM Process Parameters for Machining INCONEL 718 using Taguchi Grey Relational Analysis
(TGRA)
V. TAGUCHI METHOD AND GREY The magnitude gives the strength of the
RELATIONAL ANALYSIS (GRA) effect.

Taguchis method is an efficient tool for the design of Main Effects Plot for SN ratios
a high quality manufacturing system; it is employed Data Means

when the number of parameters is high. Dr. Genichi -15

Pulse OnTime Pulse Off Time Water Pressure Wire Feed Wire Tension

Taguchi, a Japanese engineer has developed a method -16

based on orthogonal arrays (OA). In this method

Mean of SN ratios
quality is measured by the deviation of a -17

characteristic from its target value. A loss function is -18

developed from this deviation. Uncontrollable factors

which are also known as noise cause such deviation
-19

and result in loss. Taguchi method seeks to minimize -20

the noise because the elimination of noise factor is 120 125 130 50 55 60 5 10 15 1 2 3 7 8 9

impractical and so a parameter called signal to noise Signal-to-noise: Larger is better

ratio (S/N) is defined. Fig.3 Main Effects Plot for S/N ratios for effects of control
factors on MRR

To solve multiple performance characteristic

From the fig.3, it can be seen that optimal conditions
problems, the Taguchi method is coupled with grey
obtained from the graph are pulse on-time 125, pulse-
relational analysis. In GRA experimental data are first
off time 50, water flowrate 15, wire feed 3 and wire
normalized in the range of zero to one. Grey
tension 7.
relational coefficients are calculated to represent the
correlation between the ideal and the actual
Table III Response table for Signal to Noise ratios for
normalized data.
MRR
Leve Puls Puls Water Wire Wire
l e on- e flowrat feed tensio
time off- e n
time
1 - - -17.09 - -16.78
20.2 16.4 17.0
4 8 5
2 - - -17.07 - -17.00
15.2 17.0 17.3
2 3 2
3 - - -16.98 - -17.36
15.6 17.6 16.7
8 3 7
Delta 5.01 1.16 0.11 0.55 0.58
Rank 1 2 5 4 3

According to the results presented in Table III, for

MRR, Pulse on-time has the largest effect on the
Fig.2 Flow Chart of Taguchis method multiple process parameter indexes. Pulse off-time is
second and is followed by factor Wire Tension, factor
VI. EXPERIMENTATION Wire Feed and factor Water flowrate.

According to the standard L27 array the input Main Effects Plot for SN ratios
parameters is and the output parameters for the Data Means

respective combinations are calculated and are

Pulse OnTime Pulse Off Time Water Pressure Wire Feed Wire Tension
-15

tabulated in the table VII (appendix). A main effect -16

plot is a plot of the mean response values at each

Mean of SN ratios

-17

level of a design parameter or process variable, this

plot can be used to compare the relative strength of
-18

the effects of the various factors. The sign and -19

magnitude of a main effect plot would give -20

information on the following: -21

The sign of a main effect gives the direction

120 125 130 50 55 60 5 10 15 1 2 3 7 8 9

Signal-to-noise: Smaller is better

of the effects starting average response value Fig.4 Main Effects Plot for S/N ratios for effects of control
increases or decreases. factors on WWR

Proceedings of 09th IRF International Conference, 27th July-2014, Bengaluru, India, ISBN: 978-93-84209-40-7
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 Multi-Response Optimization of CNC WEDM Process Parameters for Machining INCONEL 718 using Taguchi Grey Relational Analysis
(TGRA)
From the fig.4, it can be seen that optimal conditions 2 3.91 4.42 4.525 4.67 4.790
obtained from the graph are pulse on-time 120, pulse- 8 0 4
off time 55, water flowrate 15, wire feed 1 and wire
tension 8. 3 5.23 4.52 4.766 4.59 4.523
2 5 1
Table IV Response table for Signal to Noise ratios for Delt 1.31 0.31 0.381 0.26 0.426
WWR a 4 3 1
Leve Puls Puls Water Wire Wire
l e on- e flowrat feed tensio Rank 1 4 3 5 2
time off- e n
time
1 - - -18.35 - -19.19 According to the results presented in table V, for Kerf
15.2 18.3 16.3 Width, Pulse on time has the largest effect on the
2 9 7 multiple process parameter indexes. Wire Tension is
2 - - -18.71 - -16.72 second and is followed by factor Water flowrate,
19.4 18.2 18.2 factor Pulse off-time and factor Water Feed.
9 4 0
3 - - -17.93 - -19.08 Taguchis experimental design was used to produce
20.2 18.3 20.4 the output samples and analyze the effect of each of
7 5 1 the controllable factors on multiple responses. A level
Delt 5.05 0.15 0.78 4.04 2.47 average analysis was adopted to interpret the results.
a This analysis is based on combining the data
Rank 1 5 4 2 3 associated with each level of each factor. The
difference in the average results for the highest and
lowest average response is the measure of the effect
According to the results presented in Table IV, for
of that factor. The greatest value of this difference is
WWR, Pulse on-time has the largest effect on the
related to the larger effects of that particular factor.
multiple process parameter indexes. Wire Feed is
Data preprocessing of each performance
second and is followed by factor Wire Tension, factor
characteristic and the experimental results for the
Water flowrate and factor Pulse off-time.
grey relational according to formulae listed in
optimization techniques.
Main Effects Plot for SN ratios
Data Means
Pulse OnTime Pulse Off Time Water Pressure Wire Feed Wire Tension
By using the Grey Relation method the output values
5.4
which are the experimental results were first
5.2 normalized and then the grey relational coefficient
5.0 was calculated from the normalized experimental data
Mean of SN ratios

4.8 to express the relationship between the desired and

4.6
actual experimental data. Then, the grey relational
grade was computed by averaging the grey relational
coefficient corresponding to each process response (3
4.4

4.2
responses). The overall evaluation of the multiple
4.0
process responses is based on the grey relational
120 125 130 50 55 60 5 10 15 1 2 3 7 8 9 grade
Signal-to-noise: Smaller is better

Fig.5 Main Effects Plot for S/N rations for effects of control The kerf width was measured with the profile
factors on Kerf Width
projector of 10 magnification and a least count of
0.02mm. Kerf width of each cut was measured at
From fig.5, it can be seen that optimal conditions three different places for accurate evaluation to
obtained from the graph are pulse on-time 130, pulse record the response value.
off-time 50, water flowrate 15, wire feed 2 and wire
tension 8. The GRG is the mean of the three Grey Relational
Values that have been calculated in the three output
Table V Response table for Signal to Noise ratio of parameters that are considered. One GRV is obtained
Kerf Width for material removal rate, wire removal rate and the
Leve Puls Puls Water Wire Wire kerf width each.
l e on- e flowrat feed tensio
time off- e n The mean of the values thus obtained is known as the
time Grey Relational Grade. It is to be noted that the Grey
1 4.52 4.73 4.386 4.41 4.365 Relational Values and the Grey Relational Grade lie
8 3 3 between zero and one only.

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 Multi-Response Optimization of CNC WEDM Process Parameters for Machining INCONEL 718 using Taguchi Grey Relational Analysis
(TGRA)
Optimum parameter settings obtained from
Main Effects Plot for SN ratios
S/N Ratio Plot are Pulse On-Time = 125s,
Data Means
Pulse Off-Time = 55s, Wire Feed =
1cm/min, Water Flowrate = 5 lit/min, Wire
Pulse OnTime Pulse Off Time Water Pressure Wire Feed Wire Tension
-4.5
Tension = 7g.
The kerf width is mainly influenced by Pulse
-5.0
On-Time followed by Wire Tension, Water
M e a n o f S N r a t io s

flowrate, Pulse Off-Time and lastly Wire

-5.5 Feed.

The MRR is mainly influenced by Pulse On-

Time followed by Pulse Off-Time, Wire
-6.0

Tension, Wire Feed and Water flowrate.

-6.5

The WWR is mainly influenced by Pulse

120 125 130 50 55 60 5 10 15 1 2 3 7 8 9 On-Time followed by Wire Feed, Wire
Signal-to-noise: Larger is better Tension, Pulse Off-Time and Water
Fig.6 Main Effects Plot for S/N rations for effects of control flowrate.
factors on the Grey Relational Grade
REFERENCES
From fig.6, it can be seen that optimal conditions
obtained from the graph are pulse on-time 125, pulse [1] Ricky Agarwal, Optimization of Process Parameters of
off-time 55, water flowrate 5, wire feed 1 and wire Micro Wire EDM, Bachelor thesis, (2010).
tension 7. [2] Mohd Syafiq Bin Dzulkapli, Study the effect of Wire-EDM
parameters on surface roughness for machining die-steel,
Table VI Response Table for Signal to Noise Ratios Bachelor thesis, (2008).
for the Grey Relational Grade [3] J. T. Huang, Y. S. Liao, Optimization of machining
Leve Puls Puls Water Wire Wire parameters of Wire-EDM based on Grey relational and
l e on- e flowrat feed tensio statistical analyses, International Journal of Production
Research, (2003) pp.1707-1720.
time off- e n
time [4] Manoj Kumar Mahonta, Optimization of micro wire
electric discharge machining using aerospace material,
Master thesis, (2013).
1 - - -5.739 - -5.479
6.37 5.90 4.96 [5] A. Gosawami, J. Kumar, Investigation of surface integrity,
0 8 6 material removal rate, and wire wear ratio for WEDM of
Nimonic 80A alloy using GRA and Taguchi method,
Engineering Science and Technology, an International
2 - - -5.958 - -5.552 Journal (2014).
4.52 5.57 6.26 http://dx.doi.org/10.1016/j.jestch.2014.05.002.
4 3 5
[6] El-Hofy Hassan, Advanced Machining Processes, McGraw-
3 - - -5.861 - -6.529 Hill Publishing Company Limited, New York, USA, (2003).
6.66 6.07 6.32
[7] H. Singh, R. Garg, Effects of process parameters on
4 7 8 material removal rate in WEDM, Journal of Achievements
Delta 2.14 0.50 0.219 1.36 1.050 in Materials and Manufacturing Engineering, (2009) pp.70-
0 4 3 74.
Rank 1 4 5 2 3 [8] S. Sivakiran, C. Bhaskar Reddy, C. Eswara Reddy, Effect
Of Process Parameters On MRR In Wire Electrical
According to the results presented in table VI, for the Discharge Machining Of En31 Steel, International Journal
of Engineering Research and Applications (IJERA), (2012)
Grey relational grade, Pulse on-time has the largest pp.1221-1226.
effect on the multiple process parameter indexes.
[9] S. V. Subrahmanyam, M. M. M. Sarcar, Evaluation of
Wire Feed is second and is followed by factor Wire Optimal Parameters for machining with Wire cut EDM
Tension, factor Pulse off-time and factor Water Using Grey-Taguchi Method, International Journal of
flowrate. Scientific and Research Publications, ISSN 2250-3153
(2013).
CONCLUSION [10] Edwin B. Dean, Taguchi Approach to Design Optimization
for Quality and Cost: An Overview, International Society
Multi Response Optimization of WEDM on of Parametric Analysts, (1991).
INCONEL 718 plate using Taguchi Grey Relational [11] Wei-Chung Weng, Fan Yang, Atef Z. Elsherbeni, Linear
Analysis (TGRA) was experimentally investigated in Antenna Array Synthesis Using Taguchis Method: A Novel
Optimization Technique in Electromagnetics, IEEE
this project. Transactions on Antennas and Propagation, (2007) pp.723-
730.

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 Multi-Response Optimization of CNC WEDM Process Parameters for Machining INCONEL 718 using Taguchi Grey Relational Analysis
(TGRA)
APPENDIX
Table VII Experimental results for the input parameters along with the normalized values of output parameters
Norm Normalized value
S. Pulse Pulse Water Wire Wire WWR MRR KW WWR MRR KW
No on- off- flowrate feed tension Norm Norm Norm
time time
1 120 60 5 1 8 2.96 0.085 0.61 0.976 0.02 0.5

2 120 60 10 2 7 6.624 0.082 0.6 0.529 0 0.444

3 120 60 15 3 9 10.129 0.084 0.62 0.102 0.018 0.556

4 120 55 5 2 7 6.627 0.089 0.63 0.529 0.061 0.611

5 120 55 10 3 9 10.215 0.093 0.58 0.091 0.096 0.333

6 120 55 15 1 8 2.905 0.097 0.57 0.983 0.133 0.278

7 120 50 5 3 9 10.246 0.125 0.63 0.088 0.388 0.611

8 120 50 10 1 8 2.765 0.118 0.56 1 0.326 0.222

9 120 50 15 2 7 6.401 0.112 0.55 0.557 0.270 0.167

10 125 60 5 2 9 6.443 0.152 0.58 0.551 0.629 0.333

11 125 60 10 3 8 10.128 0.164 0.59 0.102 0.733 0.389

12 125 60 15 1 7 10.965 0.178 0.7 0 0.856 1

13 125 55 5 3 8 10.212 0.178 0.69 0.092 0.856 0.944

14 125 55 10 1 7 10.037 0.194 0.68 0.113 1 0.889

15 125 55 15 2 9 6.333 0.178 0.62 0.565 0.856 0.556

16 125 50 5 1 7 10.804 0.178 0.66 0.020 0.856 0.778

17 125 50 10 2 9 10.806 0.164 0.67 0.019 0.733 0.833

18 125 50 15 3 8 10.845 0.178 0.56 0.015 0.856 0.222

19 130 60 5 3 7 10.862 0.178 0.55 0.013 0.856 0.167

20 130 60 10 1 9 10.871 0.152 0.57 0.011 0.629 0.278

21 130 60 15 2 8 10.765 0.164 0.54 0.024 0.733 0.111

22 130 55 5 1 9 10.807 0.152 0.57 0.019 0.629 0.278

23 130 55 10 2 8 10.887 0.164 0.55 0.024 0.733 0.167

24 130 55 15 3 7 10.887 0.178 0.54 0.010 0.856 0.111

25 130 50 5 2 8 10.765 0.164 0.53 0.024 0.733 0.056

26 130 50 10 3 7 10.887 0.178 0.56 0.010 0.856 0.222

27 130 50 15 1 9 7.0357 0.152 0.52 0.479 0.629 0

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Multi-Response Optimization of CNC WEDM Process Parameters for Machining INCONEL 718 using Taguchi Grey Relational Analysis
(TGRA)
Table VIII Delta values and Grey relational grades
S. No Delta WWR Delta MRR Delta KW X1 X2 X3 SI
1 0.0238 0.971 0.5 0.955 0.340 0.5 0.598
2 0.471 1 0.556 0.515 0.333 0.474 0.440
3 0.898 0.982 0.444 0.357 0.337 0.529 0.408
4 0.471 0.939 0.389 0.515 0.347 0.563 0.475
5 0.909 0.904 0.667 0.355 0.356 0.429 0.380
6 0.017 0.867 0.723 0.967 0.366 0.409 0.581
7 0.912 0.612 0.389 0.354 0.450 0.563 0.455
8 0 0.674 0.778 1 0.426 0.391 0.606
9 0.443 0.730 0.833 0.530 0.407 0.375 0.437
10 0.449 0.371 0.667 0.527 0.574 0.429 0.510
11 0.898 0.267 0.611 0.358 0.652 0.45 0.487
12 1 0.144 0 0.333 0.776 1 0.703
13 0.908 0. 144 0.055 0.355 0.776 0.9 0.677
14 0.887 0 0.111 0.361 1 0.818 0.763
15 0.435 0. 144 0.444 0.535 0.776 0.529 0.613
16 0.980 0. 144 0.222 0.338 0.776 0.692 0.602
17 0.981 0.267 0.167 0.338 0.652 0.75 0.580
18 0.985 0. 144 0.778 0.337 0.776 0.391 0.501
19 0.987 0. 144 0.833 0.336 0.776 0.375 0.496
20 0.989 0.371 0.722 0.336 0.574 0.409 0.440
21 0.976 0. 267 0.889 0.339 0.652 0.36 0.450
22 0.981 0. 371 0.722 0.338 0.574 0.409 0.440
23 0.976 0.267 0.833 0.339 0.652 0.375 0.455
24 0.990 0. 144 0.889 0.335 0.776 0.36 0.490
25 0.976 0. 267 0.944 0.339 0.652 0.346 0.446
26 0.990 0. 144 0.778 0.335 0.776 0.391 0.501
27 0.521 0.371 1 0.490 0.574 0.333 0.466

Fig.7 Experimental setup for WEDM

Proceedings of 09th IRF International Conference, 27th July-2014, Bengaluru, India, ISBN: 978-93-84209-40-7
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