Multi responses optimization of wire EDM process parameters using Taguchi approach coupled with principal component analysis methodology

The wire EDM was known as for its better efficiency to machining hardest material and give precise and accurate result comparing to other machining process. The intent of this experimental paper is to optimize the machining parameters of Wire Electrical Discharge Machining (WEDM) on En45A Alloy Steel with the approach of Principal component Analysis (PCA). Three control variables Open Voltage (OV), Servo Voltage (SV), & Wire Feed (WF) are considered in this study to see their effect on three responses ie. Metal Removal Rate (MRR), Machining Time (MT) and Gap voltage (GV). The experiment has been conducted as per Taguchi’s L 9 Orthogonal Array (OA). The Total principal component index (TPCI) is find out by using PCA methodology. There after ANOVA is applied to find out the percentage contribution of the process variables. It has been found that the open voltage (OV) is the most effecting variable on multiple responses. Keywords: En45A alloy steel, wire electrical discharge machining (WEDM), Taguchi’s orthogonal array (OA), Principal component analysis (PCA), ANOVA