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This study examines how to optimize the parameters of the procedure in WEDM of tungsten carbide using the Taguchi method. The performance of the machining was assessed according to two critical responses: MRR and Ra. An electrode made of brass wire was used for the experiments, and a Taguchi L9 orthogonal array was employed to design the experimental trials with three input parameters “Current, Ton, and Toff” each at three levels. Analysis of Variance (ANOVA) and main effect plots were utilized to ascertain each parameter’s importance and contribution. The results reveal that peak Current has the most dominant influence on both MRR and surface roughness, contributing 89.16% and 86.47% respectively. Increasing the Current significantly improves the MRR but adversely affects the surface quality. Pulse-on time had a moderate effect, whereas pulse-off time had a minimal impact. It was determined which set of parameters will maximize MRR and minimize Ra., demonstrating the efficacy of the Taguchi approach for process optimization in hard material machining. This research offers valuable insights for improving productivity and surface quality in precision machining of tungsten carbide using WEDM.

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Performance Improvement of WEDM in Tungsten Carbide Machining Through Taguchi-Based Parameter Optimization

  • 会议论文

  • 发表日期：

    2026年

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  • B. Selva Babu,
  • S. Sathiyaraj,
  • A. Logesh,
  • P. Vishnu

摘要

This study examines how to optimize the parameters of the procedure in WEDM of tungsten carbide using the Taguchi method. The performance of the machining was assessed according to two critical responses: MRR and Ra. An electrode made of brass wire was used for the experiments, and a Taguchi L9 orthogonal array was employed to design the experimental trials with three input parameters “Current, Ton, and Toff” each at three levels. Analysis of Variance (ANOVA) and main effect plots were utilized to ascertain each parameter’s importance and contribution. The results reveal that peak Current has the most dominant influence on both MRR and surface roughness, contributing 89.16% and 86.47% respectively. Increasing the Current significantly improves the MRR but adversely affects the surface quality. Pulse-on time had a moderate effect, whereas pulse-off time had a minimal impact. It was determined which set of parameters will maximize MRR and minimize Ra., demonstrating the efficacy of the Taguchi approach for process optimization in hard material machining. This research offers valuable insights for improving productivity and surface quality in precision machining of tungsten carbide using WEDM.