Optimization of WEDM Process with Molybdenum Wire Electrode using GRA

The correct selection of manufacturing conditions and technique is one of the most important aspects to take into consideration in the majority of manufacturing processes and, particularly, in processes related to Wire Electrical Discharge Machining (WEDM). Optimization is one of the techniques used in manufacturing sectors to arrive for the best manufacturing conditions, which is an essential need for industries towards manufacturing of quality products at lower cost. This paper aims to investigate the optimal set of process parameters such as peak current, gap voltage, pulse on time, pulse off time and wire tension in WEDM process to identify the variations in performance characteristics such as cutting rate and surface roughness for machining D2 tool steel using the molybdenum wire electrode. Based on the experiments conducted using response surface methodology, analysis has been carried out using Grey Relational Analysis. The confirmation experiments were carried out to validate the optimal results. Thus, the machining parameters for WEDM were optimized for achieving the combined objectives of higher cutting rate and lower surface roughness. Grey relational Analysis is being effective technique to deal with multi objective optimization problem.