Experimental investigation on die corner accuracy for wire electrical discharge machining of Monel 400 alloy

The experimental research presented in this article explores the wire electrical discharge machining of Monel 400 alloy. An L-18 orthogonal array has been used for experimentation by considering machine controllable factors (i.e. wire tension, pulse-on time, pulse frequency, peak current and servo voltage) and machine uncontrollable factors (namely flushing nozzle height, workpiece thickness and corner angle) as process parameters. Using Taguchi methodology, the influence of the process parameters on the responses, such as material removal rate, surface roughness and corner error, were studied. The impact of pulse parameters modification in corner accuracy improvement has been analyzed. Finally, using Taguchi’s additive model predictions and Pareto optimality approach, a sample technology table for a specific machining condition has been reported for ready use.