Optimization of process parameters for metal removal rate in case of WEMM using Continuous DC supply by Taguchi methods and ANOVA Analysis

Abstract

Wire Electrochemical Micromachining is a relatively new method of machining using electrochemical dissolution; it utilizes the principle of electrolysis and uses a micro-wire for metal removal to produce micro metal parts. Since there is no tool wear, a thinner wire can be used in this process. In the present study, Wire electrochemical machining input parameters are optimized using Taguchi approach for maximum metal removal rate. In this study continuous DC power supply is used for metal removal and the tool is made up of copper wire. After analysis, the optimum parameter range came out to be 200 g/l of electrolyte concentration and 24 V of machining voltage. The electrolyte used is aqueous Sodium Chloride solution.