Pujari Srinivasa Rao et al.

/ International Journal of Engineering Science and Technology

Vol. 2 (12), 2010, 7729-7739

Prediction of Material removal rate for

Aluminum BIS-24345 Alloy
in wire-cut EDM
PUJARI SRINIVASA RAO*
Department of Mechanical Engineering, GITAM University,
Visakhapatnam, Andhra Pradesh, India
pujari.vizag@gmail.com

Dr. KOONA RAMJI

Department of Mechanical Engineering, Andhra University,
Visakhapatnam, Andhra Pradesh, India
ramjidme@yahoo.co.in

Prof. BEELA SATYANARAYANA

Vice-Chancellor, Andhra University,
Visakhapatnam, Andhra Pradesh, India
snbeela@yahoo.com

Abstract :

In the present work, the parametric optimization method using Taguchi’s robust design is proposed for wire-cut
electric discharge machining of Aluminum BIS-24345 alloy. In the recent past this material gained dominance,
where high strength and/or hardness is required at elevated temperatures. So, experimentation has been done by
using Taguchi’s L18 (21x37) orthogonal array. Each experiment was conducted under different conditions of
pulse on time, pulse off time, peak current, flushing pressure of dielectric fluid, wire feed rate, wire tension,
spark gap voltage and servo feed setting. The response of material removal rate is considered for improving the
machining efficiency. Optimal combinations of parameters were obtained by this method. Mathematical and
artificial neural network models has been developed relating the machining performance and process
parameters. The study shows that the Taguchi’s method is suitable to solve the stated problem with minimum
number of trails as compared with a full factorial design.

Keywords: Wire-cut EDM; Orthogonal array; Taguchi’s method; ANN; Regression analysis.

1. Introduction

Wire-cut electrical discharge machining of Aluminum BIS-24345 alloy has been considered in the present set of
research work. This material is rapidly growing its applications in the field where it requires high strength
and/or hardness including at elevated temperature uses. Specific applications include aircraft, ordnance and
general engineering apart from this truck structural’s, fittings, fasteners and is one of the strongest heat treatable
alloys for screw machine applications. To obtain various structural components of Aluminum BIS-24345 alloy
the wire-cut EDM process plays a predominant role in some manufacturing sectors, because this process has the
capacity to cut complex and intricate shapes of components in all electrically conductive materials with better
precision and accuracy. However the efficiency of machining is low as compared to the conventional
machining. Machining parameter tables provided by the machine tool manufacturers often do not meet the
operator requirements and sometimes even do not provide efficient guidelines to manufacturing engineers.
Therefore it is troublesome to establish a model that can accurately predict the performance by correlating the
process parameter. Wire-cut EDM consists of a number of parameters, which makes it difficult to obtain optimal
parametric combinations for machining these materials. So, a proper design of experiments (DOE) should to be
conducted to perform more accurate, less costly and more efficient experiments [10]. Taguchi’s robust design is
an important tool for design of experiments which offers a simple and systematic approach to optimize design

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for performance, quality and cost. The plan of experiments consists of acquiring data in a controlled way,
executing these experiments and analyzing the data, in order to obtain information about the behavior of a given
process. Two major tools used in Taguchi’s design are signal to noise ratio, which measures quality with
emphasis on variation and orthogonal arrays (OA), which accommodates many design factors simultaneously.
Orthogonality means that the factors can be evaluated independently of one another; the effect of one factor
does not bother the estimation of another factor. The real power in using an OA is the ability to evaluate several
factors in a minimum number of tests when compared to full factorial experiments. By applying this technique
one can significantly reduce the time required for experimental investigation and can determine which factor has
more influence and which has less. In order to improve the performance measures namely surface roughness,
cutting speed, dimensional accuracy and material removal rate of the WEDM process several researches were
attempted previously. [Aminollah Mohammadi et al. (2008)] optimized machining parameters for improvement
of surface roughness in wire electrical discharge turning. [Ramakrishnan and Karunamoorthy (2008)] developed
an artificial neural network model for optimization of inconel 718 on machining of CNC WEDM process. [Rao
and Sarcar (2009)] evaluated the optimal parameters for machining brass with wire and studied the influence of
these parameters on MRR and surface roughness. [Mahapatra and Patnaik (2007)] optimized the wire electrical
discharge machining parameters. [Spedding and Wang (1997)] developed responsive surface methodology
(RSM) and artificial neural network (ANN) models for the WEDM process. The ANN model is found to fit the
data better and have a higher predictive capability of surface roughness value Ra and cutting speed.
[Karthikkeyan, et al. (1999)] modeled EDM using a full factorial design while machining silicon carbide
particulate composites. [Rozenek et al. (2001)] used a metal matrix composite as work piece material and
investigated the variation of machining feed rate and surface roughness with machining parameters. [Tsai and
Wang (2001)] adopted neural network models to predict the surface finish. [Qu et al. (2002)] derived a
mathematical model for the material removal rate of cylindrical wire-cut EDM process. [Manna and
Bhattacharya (2005)] developed a dual response approach for the hard SiC particles of Al/SiC-MMC which
intermittently comes into contact to the hard surface during conventional machining act as small cutting edges
like those of a grinding wheel on the cutting tool edge that, in due course, are worn out by abrasion.

The main objective of this paper is to study different parameters of the WEDM using Taguchi’s design
methodology and standard matrix experiments L18 (21X37) orthogonal array to prepare the models for machining
of Aluminum BIS-24345 alloy. In several references it is found that very few researches considered parameters
like servo gap voltage and servo feed rate setting which also have significant effect on MRR. In this paper, in
addition to the parameters like Pulse on time, Pulse off time, Peak current, Flushing pressure of dielectric fluid,
Wire feed rate setting, Wire tension setting the above said parameters are also considered. The results obtained
are analyzed for the selection of an optimal combination of WEDM parameters for the proper machining of
Aluminum BIS-24345 alloy to achieve better material removal rate. Four different analyses were made on the
data obtained from the experiments. Firstly, analysis of variance (ANOVA) is carried out to help one determine
significant factors. Secondly, signal-to-noise (S/N) ratio analysis is conducted to find the optimal settings and
factor levels. Thirdly, regression analysis establishes a relationship between factors and responses. Lastly, a
feed-forward back propagation artificial neural network has been build to enhance the ability to predict the
material removal rate.

2. Experimental Design

2.1 Experimental Set-Up and wire electrode

All the experiments were conducted on Ultra Cut 843/ ULTRA CUT f2 CNC Wire-cut EDM machine shown in
Fig: 1. In this machine, all the axes are servo controlled and can be programmed to follow a CNC code which is
fed through the control panel. All three axes have an accuracy of 1μm. Through an NC code, machining can be
programmed. Wire-cut electrical discharge machining of Aluminum BIS-24345 alloy has been considered in the
present set of research work. The chemical composition of the material given by the energy-dispersive
spectrometer (EDS) shown in Fig: 2, in percentage of mass are as follows, Si=0.74, Fe=0.195, Cu=4.70,
Mn=0.61, Mg=0.452, Zn=0.030, Ni=0.003, Cr=0.009, Pb=0.005, Sn=0.005, Ti=0.025, Li<0.001, Al=93.230.
The composition confirms that the material tested on EDS is Aluminum BIS-24345 alloy. The size of the work
piece considered for experimentation on the wire-cut EDM is 25 mm x 20 mm x 10 mm. According to the
Taguchi method based on robust design a L18 (21X37) mixed orthogonal array is employed for the
experimentation. Among the eight WEDM parameters two levels for one control factor (Pulse on time) and
three levels for remaining seven control factors, are considered for optimality analysis during machining of
Aluminum BIS-24345 alloy. Table: 1 shows WEDM parameters and their levels.

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2.2 Data collection:

The cutting speed data (Vc, mm/min) is directly displayed on the computer monitor of the machine tool, Ultra
Cut 843/ ULTRA CUT f2 for various settings of experimental machining operation. From this data Material
removal rate is calculated as follows
MRR = Vc * b* h mm3/min
Where :
Vc= Cutting speed in mm/min
b = Width of cut in mm
h = Height of the work piece in mm

Fig: 1 Ultra Cut 843/ ULTRA CUT f2 CNC Wire-cut EDM

Fig: 2 Work piece material on the EDS
machine

3.Taguchi Method:

3.1 Steps in Taguchi Methodology:

The major initial steps in designing, conducting and analyzing the experiment are
Step (1): Selection of factors and/or interactions to be evaluated
Step (2): Selection of number of levels for the factors
Step (3): Selection of the appropriate OA
VLN ≥ V required for factors and interactions
VLN = N-1
(1)
Where
VLN = The total degrees of freedom
N = Total number of experiments
V = Degrees of freedom available in OA
In this study, the total number of experiments is 18; hence total degree of freedom available as per Eq. (1) is
17.Whereas total degrees of freedom for factors and interactions available are 15. So the condition for the
selection of appropriate OA is satisfied.
Step (4): Assignment of factors and/or interactions to columns
Step (5): Conduct tests
Step (6): Analyze results
Step (7): Confirmation experiment
Table: 1 wire EDM parameters and their levels

Sl.No. Parameters Symbol Level 1 Level 2 Level 3 Units

1 Pulse On time TON 105 110 --- µ sec
2 Pulse Off time TOFF 53 58 62 µ sec
3 Peak Current IP 10 11 12 Ampere
4 Flushing pressure of dielectric fluid WP 5 7 11 Kg/cm2
5 Wire Feed rate setting WF 5 7 10 m/min
6 Wire tension setting WT 5 7 10 Kg-f
7 Spark gap Voltage Setting SV 8 15 22 Volts
8 Servo Feed Setting SF 500 1500 2100 mm/min

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3.2 Analysis of Variance (ANOVA):

The purpose of ANOVA experimentation is to reduce and control the variation of a process; subsequently, deci-
sions can be made concerning which parameters affect the performance of the process. ANOVA is the statistical
method used to interpret experimental data to make the necessary decisions. Through ANOVA, the parameters
can be categorized into significant and insignificant machining parameters. Table: 2 shows the ANOVA and F-
test values with percentage of contribution (i.e. the effectiveness of the individual WEDM parameters) on the
material removal rate during the machining of Aluminum BIS-24345 alloy.

Table: 2 ANOVA table for material removal rate

Source/Parameters
(Symbol) D.F SS V F %p
TON(A) 1 60065.78 60065.78 20.15593 11.57034
TOFF(B) 2 41502.87 20751.43 6.96344 7.994607
IP(C) 2 327655 163827.5 54.97465 63.11546
WP(D) 2 17056.92 8528.46 2.861847 3.285637
WF(E) 2 657.12 328.56 0.110253 0.12658
WT(F) 2 4311.09 2155.545 0.723324 0.830436
SV(G) 2 31172.07 15586.03 5.230117 6.004608
SF(H) 2 30754.89 15377.44 5.160121 5.924247
Error 2 5960.11 2980.055 1.148083
Total 17 519135.8

Where D.F = Degrees of Freedom; SS= Sums of square; V= Variance;

F= Fisher value; %p = Percentage of contribution

3.3 Signal-to-Noise ratios (S/N ratio):

According to Taguchi method, the S/N ratio is the ratio of signal to noise where signal represents the desirable
value (i.e., the mean for the output characteristics), and noise represents the undesirable value (i.e., the square
deviation for the output characteristics). Therefore, the S/N ratio is the ratio of mean to square deviation. It is
denoted by ‘η’ with a unit of dB. According to Quality Engineering, the characteristic that higher observed
value represents better machining performance, as in case of MRR, is known as “higher is better”. Inversely,
the characteristic that lower value represents better machining performance, such as surface roughness, is
called ‘lower is better’. Therefore, for MRR ‘higher is better’ is selected for obtaining optimum machining
performance characteristics. The S/N ratio can be calculated as a logarithmic transformation of the loss
function as shown in Eq. (2). The S/N ratio values are calculated for the experiments conducted on the
Aluminum BIS-24345 alloy, and the obtained values are tabulated in Table: 3.

S/N ratio for Material removal rate,

10 ∑
(2)

3.4 Analysis of Data:

Regardless of the category of performance characteristics, a greater η value corresponds to a better

performance. Therefore optimal level of machining parameters is the level with greatest η value. The S/N
ratio values for each experiment of L18 (21X37) was calculated, based on the analysis of S/N ratio, the optimal
machining performance for each parameter is obtained and tabulated in Table: 4. The Material removal rate
was obtained at 110 µs Pulse on time (level 2), 53 µs Pulse off time (level 1), 12 ampere for Peak Current
(level 3), 5 Kg/cm2 Flushing pressure of dielectric fluid (level 1), 10 m/min Wire Feed rate setting (level 3), 7
Kg-f Wire tension setting (level 2), 15 Volts Spark gap Voltage Setting (level 2) and 2100 mm/min Servo
feed Setting (level 3). From this, it is concluded that for maximum material removal rate, the optimal
parametric combination is A2B1C3D1E3F2G2H3. The above results are shown graphically in Figs: 3 to 10.

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3.5 Confirmation Experiment:

The confirmation experiment is the final step in the Taguchi’s design of experiment (DOE) process. The
purpose of the confirmation experiment is to validate the conclusions drawn during the analysis phase. The
confirmation experiment is performed by conducting a test with specific combination of factors and levels
previously evaluated. In this study, after determining the optimum levels, a new experiment is designed and
conducted with optimum levels of the machining parameters. The final step is to predict and verify the
improvement of the performance characteristics. The predicted S/N ratio using the optimal levels of the
machining parameters can be calculated as in Eq. (3).
η η ∑ η η (3)
where:
ηopt = Predicted optimal S/N ratio
ηm = Total mean of the S/N ratios
ηj = Mean S/N ratio at the optimal levels
k = Number of main design parameters that affect the quality characteristics

Confirmation test results proved that the determined optimal combination (A2B1C3D1E3F2G2H3 ) of
machining parameter, with respect to the actual chosen initial setting (i.e., A2B2C2D2E2F2G2H2) improves
the S/N ratio, satisfying the real requirement of wire-cut EDM operations for the proper machining of
Aluminum BIS-24345 Alloy. The improvement in S/N ratio from the initial machining parameters to the
level of optimal machining is 8.31238 dB. So, material removal rate is greatly improved by this approach.
The confirmation experiment shows that, the used Taguchi’s method enhanced the machining performance
and optimized the machining parameters.
Table: 3 Experimental design using L18 (21X37) orthogonal array

Sl.No TON TOFF IP WP WF WT SV SF MRR S/N ratio

1 105 53 10 5 5 5 8 500 110.4 40.85938
2 105 53 11 7 7 7 15 1500 452.7 53.11621
3 105 53 12 11 10 10 22 2100 603 55.60635
4 105 58 10 5 7 7 22 2100 252.6 48.04867
5 105 58 11 7 10 10 8 500 227.4 47.13581
6 105 58 12 11 5 5 15 1500 444.9 52.96525
7 105 62 10 7 5 10 15 2100 139.8 42.91014
8 105 62 11 11 7 5 22 500 150.3 43.53918
9 105 62 12 5 10 7 8 1500 393 51.88785
10 110 53 10 11 10 7 15 500 241.5 47.65834
11 110 53 11 5 5 10 22 1500 562.5 55.00245
12 110 53 12 7 7 5 8 2100 592.8 55.45816
13 110 58 10 7 10 5 22 1500 279 48.91208
14 110 58 11 11 5 7 8 2100 362.7 51.19095
15 110 58 12 5 7 10 15 500 599.4 55.55433
16 110 62 10 11 7 10 8 1500 156.6 43.89584
17 110 62 11 5 10 5 15 2100 491.7 53.834
18 110 62 12 7 5 7 22 500 527.7 54.44774

Table: 4 Mean S/N Ratios at each level for all the Parameters

Level TON TOFF IP WP WF WT SV SF

1 48.4521 51.2834 45.3807 50.8644 49.5626 49.2613 48.4046 48.1991
2 51.7726 50.6341 50.6364 50.3300 49.9353 51.0582 51.0063 50.9632
3 48.4191 54.3199 49.1426 50.8390 50.0174 50.9260 51.1747

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TON WF
53 51
Mean η (dB) for
52

Mean η (dB) for

51 51.7726 50.5 50.839
50
MRR

49 S/N
50

MRR
48.452 49.9353
48 S/N
47 49.5
49.5626
46
49
Level 1 Level 2
48.5
Level 1 Level 2 Level 3
Fig No: 3 Average S/N ratios (dB) Vs Pulse ON Time (µs) Fig No: 7 Average S/N ratios (dB) to Wire Feed rate setting (m/min)

TOFF 51.5
WT

Mean η (dB) for

52 51.2834 51
50.6341 51.0582
Mean η (dB) for

51 50.5

MRR
50 50
50.0174 S/N
MRR

S/N  49.5
49 48.4191
49 49.2613
48
48.5
47 48
46
Level 1 Level 2 Level 3
Level 1 Level 2 Level 3
Fig No: 4 Average S/N ratios (dB) Vs Pulse OFF Time (µs) Fig No: 8 Average S/N ratio (dB) to Wire tension setting (Kg-f)

SV
IP 52
Mean η (dB) for

55 54.3199
51
Mean η (dB) for

50.6364 51.0063 50.926

50
MRR

50 S/N
MRR

49
S/N
45.3807 48
45 48.4046
47
40 Level 1 Level 2 Level 3
Level 1 Level 2 Level 3
Fig No: 5 Average S/N ratio (dB) Vs Peak Current (ampere) Fig No: 9 Average S/N ratio (dB) Vs Spark gap Voltage Setting (volts)

SF
WP 52
Mean η (dB) for

51 50.8644 51 50.9632
50.33 51.1747
Mean η (dB)

50
for MRR

MRR

50 49 S/N
49.1426 S/N 48
49 47 48.1991
46
48
Level 1 Level 2 Level 3
Level 1 Level 2 Level 3
Fig No: 6 Average S/N ratios (dB) Vs Flushing pressure of dielectric fluid Fig No: 10 Average S/N ratio (dB) to Servo Feed Setting ( mm/min)
(Kg/cm2)

4. Mathematical Model for Machining Performance Criteria

Multiple linear regression models can often be an adequate representation of a more complicated structure,
within certain ranges of the independent variables. Here, Eq. (4) represents the generalized model of
multiple linear regression (MLR) analysis, which gives the relationship between response and independent

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variables. The estimated response is obtained from the generalized simple regression equation as given in
Eq. (5). In this study, material removal rate is considered as a response variable and all the eight parameters
as independent variables as given in Eq. (6). Here, MRR is the performance output term and bi (i= 0,
1….…8) are the model constants. The constants were calculated by using linear regression analysis method
with the help of MATLAB 7.7.0.471(2008b) software. The calculated coefficients from
MATLAB7.7.0.471(2008b) software were substituted in Eq. (6) and the relations so obtained were given as
in Eq. (7). Table: 5-6 shows the values obtained in predicting the material removal rate and S/N ratio values
using the developed mathematical model and the actual experimental results. Fig.11 show the good
agreement of predicted values with experimental values. The above mathematical model for material
removal rate in WEDM is of great importance for the selection of machining parameters during the
machining of Aluminum BIS-24345 alloy.

nb b ∑ x b ∑ x ………..∑ x ∑ y

b x b x b x x ……… b x x x y

: : : : : : (4)
: : : : : :
b ∑ x b ∑ x x b ∑ x x ……… b ∑ x x ∑ x y

y b b x b x b x ………….… b x
(5)

So, the mathematical model suggested here is in the following form.

MRR b b TON b TOFF b IP b WP b WF b WT b SV

b SF
(6)

MRR 3353.073 23.107 TON 13.041 TOFF 165.075 IP 13.178 WP 4.214

WF 8.386 WT 6.336 SV 0.062 SF
(7)

Fig. 11 Comparison of Experimental and predicted MRR values using Mathematical model.

5. Artificial Neural Network Modeling for WEDM

Neural networks are a highly flexible modeling tool with the ability to learn the mapping between the input
and output. A neural network is a logical structure in which multiple processing elements communicate
with each other through the interconnection between the processors. The knowledge is presented by the
interconnection weight, which is adjusted during the learning stage. In this study, MATLAB

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7.7.0.471(R2008b) version is used to create, train and test the ANNs. [Demuth and Beale (1998)] explained
the usage of neural network tool box.

5.1 Training process:

The Levenberg-Marquardt algorithm selected for training the ANN’s is a variation of the classic back
propagation that, unlike other variations that use heuristics, relies on numerical optimization techniques to
minimize and accelerate the required calculations, resulting in much faster training [Panda and Bhoi
(2005)]. The experimental data given in Table: 3 are used for training the network, the machining data
available for Aluminum BIS-24345 alloy (which is not included in the training data) is used for validation.
The machining data at initial conditions and optimal conditions are used for testing the ANN. The
performance assessment of each ANN was measured with the mean squared error (MSE) of the testing
subset. It must be noted that because of the fact that the outcome of the training greatly depends on the
initialization of weights, this is done randomly. Gradient descent with momentum weight and bias learning
function is used to minimize the mean square between the actual output pattern of the network and the
desired pattern. The transfer function used in this work is log-sigmoid on hidden layer and tan-sigmoid on
output layer.

5.2 Determination of the best model:

Before applying the neural network for modeling, the architecture of the network has been decided; i.e. the
number of hidden layers and the number of neurons in each layer. As there are 8 inputs and 1 output in the
present research work, the number of neurons in the input and output layer has to be set 8 and 1
respectively. The feed forward back-propagation architecture with one hidden layer is enough for the
majority of the applications [Fausett (1994)]. Hence, only one hidden layer has been adopted. A procedure
was employed to find the number of neurons in the hidden layer. Accordingly, an experimental approach
was adopted, which involves testing the trained neural network against another set of experimental data,
which are again drawn randomly. However, the set of combinations is different from one used for training
the network. Experimental and predicted outputs for different numbers of neurons have been compared. In
all the cases, maximum error tolerance was kept constant. It is observed that average prediction error was
minimized with 8 neurons in hidden layer. Hence, 8-8-1 neural network architecture is chosen for the task
under consideration. Once the neural network gets trained, it can provide the result for any arbitrary value
of input data set. Minimum gradient is reached at 1844 iterations. If possible, all of the combinations of the
factors should be materialized as an ANN model. Unfortunately, if all of the possible combinations of the
eight factors (one factor at two level and seven factors at three levels) were to be considered then 4374
different models would have to be created, examined and tested. This was, of course, unrealistic so this
number has to be reduced, which was accomplished through the use of OAs. It must be reminded that the
OAs are primarily used for selecting fractions out of full factorial designs and collecting all the statistically
significant data, so their use in this case is fully justified. Because of the increased computational power of
the ANNs it can deal with complex problems; for this reason ANN models are gaining more attention and
being used in new application area each day. Table: 5 show the experimental result and the model
prediction. Fig. 12 and Fig. 13 shows the neural network training window and performance plot obtained
respectively.

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Fig. 12 Neural network training window Fig.13 Performance plot of MSE Vs No.of Epochs
Table: 5 Comparisons of experimental Material removal rate data with
Mathematical and ANN model

Mathematical
Sl.No. Experimental ANN model
model
Material removal rate
1 Value obtained at Initial 458.168 432.2921 446.9937
conditions
Material removal rate
2 Value obtained at 714.999 738.8621 694.1746
Optimum conditions
Improve of Material
3 1.560 times 1.709 times 1.553 times
removal rate obtained

Table: 6 Comparison of Signal to Noise ratio (dB) values

Mathematical ANN
Sl.No. Experimental
model model
S/N ratio obtained at
1 53.220 52.715 53.006
Initial conditions

S/N ratio obtained at 57.371

2 57.086 56.830
Optimum conditions

Improve of S/N ratio

3 3.866 4.656 3.824
obtained

7. Results and Discussion

The effect of the machining parameters on material removal rate in machining Aluminum BIS-24345 alloy is
studied. From the ANOVA calculations, it is observed that, the parameter Peak Current is the most significant,
Pulse on time, Pulse off time, Spark gap voltage and Servo Feed setting are significant. Flushing pressure of
dielectric fluid, Wire feed rate setting and Wire tension setting are less significant on performance measure, i.e.,
material removal rate.

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The energy content of a single spark discharge can be expressed as a product of TON x IP. Energy contained in
a tiny spark discharge removes a fraction of workpiece material. Large number of such time spaced tiny
discharges between the workpiece and wire electrode causes the electro erosion of the workpiece material. The
experimental results obtained in machining the Aluminum BIS-24345 alloy also proved that, the parameters IP
is most significant and TON, TOFF, SV and SF are significant.

From the signal to noise ratio, optimal combination of parameters was obtained as A2B1C3D1E3F2G2H3. A
separate experiment was conducted at this optimal combination and an improved material removal rate value of
714.999 mm3/min was obtained, when compared to 458.168 mm3/min at initial machining parameters i.e.
A2B2C2D2E2F2G2H2. This improved material removal rate value is 1.560 times the initial material removal rate
(i.e. 35.92%). The S/N ratio is also improved by 3.866 dB; this is an indication of improvement in the
machining performance i.e. material removal rate.

It can be seen that MRR tends to increase significantly with increase in peak current and pulse on time due to
their dominant control over the input energy. The maximum MRR is obtained at high peak current (12 A) and
high TON (110 µ sec). It can be noted that the MRR increases with decrease in TOFF, this is because when
TOFF increases, there will be an undesirable heat loss which does not contribute to MRR. This will lead to drop
in the temperature of the workpiece before the next spark starts and therefore MRR decreases. The maximum
MRR is achieved at minimum TOFF ( 53 µ sec).

Fluctuation of average gap voltage within ± 10% of set value can be considered as a stable machining. If the gap
voltage is too low, i.e narrower discharge gap between the wire and workpiece in the direction of motion results
in larger voltage fluctuations. This in turn causes frequent wire breakage. If the gap voltage is high, on the other
hand machining speed decreases which will in turn increases the overcut. The optimum gap voltage obtained in
this case is 15 volts. Servo feed setting (SF) can be adjusted to get the optimum speed with stable gap voltage.
A mathematical model using multiple linear regression analysis was made to validate the experimental work.
The material removal rate value at optimum conditions predicted by mathematical model is 738.8621 mm3/min
which is 3.34% error when compared to experimental value (714.999 mm3/min) at the same conditions.
Similarly, the Material removal rate value at initial conditions predicted by mathematical model is 432.2921
mm3/min which is 5.64% error when compared to experimental value 458.168 mm3/min at the same conditions.
For the validation of the experimental results, in addition to the mathematical model, an artificial neural network
model with feed-forward back-propagation was adopted to enhance the prediction ability of Material removal
rate. The Material removal rate value at optimum conditions predicted by ANN model is 694.1746 mm3/min
which is 2.91% error when compared to experimental value (714.999 mm3/min ) at the same conditions.
Similarly, the Material removal rate at initial conditions predicted by ANN model is 446.9937 mm3/min which
is 2.43% error when compared to experimental value (458.168 mm3/min) at the same conditions. A good
agreement of results was obtained with mathematical model and ANN model when compared to the
experimental work.
8. Conclusion

The effects of Pulse On time, Pulse Off time, Peak Current, Flushing pressure of dielectric fluid, Wire Feed rate
setting, Wire tension setting, Spark gap Voltage Setting and Servo Feed Setting are experimentally investigated
in machining of Aluminum BIS-24345 alloy using CNC Wire-cut EDM process. The level of importance of the
machining parameters on the material removal rate is determined by using ANOVA and it is shown that IP is
most significant and TON, TOFF, SV and SF are significant. An optimum parametric combination for the
maximum material removal rate was obtained by using Signal-to-Noise (S/N) ratio. Improved S/N ratio and
conformation test indicated that it is possible to increase material removal rate by using the proposed statistical
technique. The developed mathematical model for the performance characteristic i.e. Material removal rate in
the CNC Wire-cut EDM process is successfully proposed for the proper selection of the machining parameters.
A feed-forward back propagation neural network model is developed to predict the material removal rate.
During the training process several neural network configurations were studied and it has been found that one
hidden layer with 8 neurons provides a better prediction. Hence a neural network of the type 8-8-1 was adapted
to model the process and the proposed model enhanced the prediction ability.

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