Published Paper Details:

The highest objective of this work is to estimate the Material Removal Rate (MRR), Surface Roughness (Ra) of Ti6Al4V in Wire cut Electrical Discharge Machining process by Response surface Methodology. Wire electrical discharge machining process is a vastly complex, time changing & stochastic process. The process output is pretentious by large no of input variables. Therefore a suitable selection of input variables for the wire electrical discharge machining (WEDM) process relies profoundly on the operative�s technology & knowledge because of their abundant & diverse range. WEDM is extensively used in machining of conductive materials when precision is of prime importance. Full factorial design is considered with three process parameters: TON, TOFF and IP each to be varied in three different levels. Data related to material removal rate (MRR) and surface roughness (Ra) have been measured for each experimental run; with RSM analysis Response is predicted and percentage of error has been calculated. The variation of output responses with process parameters were mathematically modeled by using non linear regression analysis. The replicas were tested for their adequacy. Result of confirmation experiments showed that the established mathematical models can predict the output responses with reasonable accuracy.