Optimisation of wire-edm process parameters for achieving low surface roughness in machining of is 5986 fe 410 steel and regression modelling

Non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters namely current (I_c), pulse-on time(T_on), pulse-off time (T_off), wirespeed (W_s) and voltage (I_v) on surface roughness (SR) is investigated while machining non-traditional machining methods are popular in the recent era for machining of various profiles in different engineering materials. In this work, the effect of critical process parameters namely current (I_c), pulse-on time(Ton), pulse-off time (T_off), wire-speed (W_s) and voltage (I_v) on surface roughness (SR) is investigated while machining of IS 5986 FE 410 steel by wire-electrical discharge machine (wire- EDM). The experiments were designed using Taguchi L16 arrays and results are analyzed using statistical methods. The process parameters such as Ic, T_off and W_s showed a significant contribution by 66.22 %, 13.77 % and 9.25 % respectively on SR. Further, the process parameters were optimized to obtain a minimum SR which produced in Ra values 1.480 µm at settings I_c -4 A, T_on- 40 µs, Ton - 10 µs, W_s- 1400 rpm and I_v- 80 V. Regression model is developed to predict the SR at different settings for the control parameters which predicted the response with average predication an error of 11.08 %