Optimization of multiple performance characteristics in wire electrical discharge machining (WEDM) process of Buderus 2080 tool steel using Taguchi-grey-fuzzy method

This paper presents an optimization of machining parameters on the material removal rate (MRR), cutting width (kerf), surface roughness (SR) and recast layer thickness (RL) of WEDM process. Buderus 2080 tool steel was selected as workpiece material. The combinations of machining parameters were determined by using Taguchi experimental design method. The four important machining parameters such as arc on time, on time, open voltage and servo voltage were taken as process variables. Optimal machining parameter were obtained by grey relational analysis and fuzzy logic method. Experimental results show that on time gives the highest contribution for reducing the total variation of the multiple responses, followed by open voltage, servo voltage and arc on time. The maximum material removal rate and minimum cutting width, surface roughness and recast layer thickness could be obtained by using the values of arc on time, on time, open voltage and servo voltage of 1 A, 2 μs, 75 V and 30 V respectively.