Int J Adv Manuf Technol (2013) 67:2269–2281

DOI 10.1007/s00170-012-4648-4

ORIGINAL ARTICLE

Modeling and multiresponse optimization on WEDM

for HSLA by RSM
Neeraj Sharma & Rajesh Khanna &
Rahul Dev Gupta & Renu Sharma

Received: 9 December 2011 / Accepted: 14 November 2012 / Published online: 28 November 2012
# Springer-Verlag London 2012

Abstract Wire electric discharge machining (WEDM) is a Pulse-on time Ton

nonconventional machining method to cut hard and conduc-
tive material with the help of a moving electrode. High-
strength low-alloy steel (HSLA) is a hard alloy with high
hardness and wear-resisting property. The purpose of this
study is to investigate the effect of parameters on cutting
speed and dimensional deviation for WEDM using HSLA as
workpiece. It is seen that the most prominent factor for
cutting speed and dimensional deviation is pulse-on time,
while two-factor interactions play an important role in this
analysis. Response surface methodology was used to optimize
the process parameter for cutting speed and dimensional
deviation. The central composite rotatable design was used
to conduct the experiments. The analysis of variance was
used for the investigation of significant factors.
Keywords Central composite rotatable design .
High-strength low-alloy steel . Multiresponse optimization .
Response surface methodology . WEDM
Abbreviation
Wire electric discharge machine WEDM
Response surface methodology RSM
High-strength low-alloy steel HSLA
Analysis of variance ANOVA
N. Sharma (*)
Department of Mechanical Engineering,
R.P. Inderaprastha Institute of Technology, Karnal, Haryana, India
e-mail: neeraj.sharma@live.com
R. Khanna : R. D. Gupta
Department of Mechanical Engineering,
Maharishi Markandeshwar Engineering College,
Maharishi Markandeshwar University, Mullana, Haryana, India
R. Sharma
E.C.E. Department,
R.P. Inderaprastha Institute of Technology, Karnal, Haryana, India
Pulse-off time Toff
Servo gap voltage SV
Peak current IP
Wire tension WT
Cutting speed CS
Dimensional deviation DD
1 Introduction and literature survey
Wire cut electric discharge machine is a thermo-electric spark
erosion process [1] used for hard-to-cut materials. The tools
used in wire electric discharge machine (WEDM) are copper,
brass, or tungsten wires. The diameter of the moving electrode
wire varies from 0.05 to 0.3 mm. The gap between the tool and
workpiece varies from 0.025 to 0.05 mm. The material is
removed with the help of a moving electrode. Various forms
of chips are flushed with the help of demonized water. With
WEDM high-dimensional accuracy, high value of surface
finish and intricate shapes can be easily obtained [2].
To investigate the literature gap or the problem formula-
tion, it is necessary to go through the various research works.
Bhatti and Hashmi [3] machined the internal and external
surfaces of components on wire cut electric discharge ma-
chine. Their research describes briefly the design and interface
of manipulator to solve the problems during research work.
The work of Rajurkar and Wang [4] is concerned on the
detection of thermal load for online control to prevent wire
breakage with the help of WEDM sparking frequency moni-
tor. Mishra, Prashad, and Banerjee [5] found that frequent
occurrence of wire rupture is one of the most serious produc-
tion constraints in electrical discharge machining (EDM) wire
cutting as after the wire break, machine tool required a lot of
time for its setting. This phenomenon restricts the cutting
speed, increases the machining time, and affects the surface
finish and accuracy adversely. Thermal load, failure through
2270
short-circuiting, and wire vibration was considered the most
important factors of wire rupture. In their work, a simple
computational model is developed which will give the tem-
perature values for varying magnitudes of parameters, viz.,
input power, pulse-on time, wire velocity, and wire diameter.
Saha et al. [6] analyzed the wire electrical discharge
machining of tungsten–carbide–cobalt composite. A
second-order multivariable regression model and a feed-
forward backpropagation neural network model have been
developed to correlate the input process parameters, such as
pulse-on time, pulse-off time, peak current, and capacitance
with the process performance namely cutting speed and
surface roughness. It was observed that neural network
architecture provide the best prediction result although the
proposed regression model was adequate and accepted. Lee
et al. [7] found that WEDM assisted by ultrasonic vibration
of the wire has better results than that of wire cut alone. For
obtaining a higher cutting rate and better surface finish
simultaneously, a high frequency of wire electrode has been
established. The simulation of the dynamic characteristics of
the wire electrode under the action of continuous discharge
forces show that ultrasonic vibration facilitates the shift of
the discharge points and improves their distribution. A set of
statistical experiments has been designed to analyze the
utilization of the pulse. It is investigated that with ultrasonic
vibration, there is a greater utilization of energy, which is a
critical factor in securing an increase in the cutting rate. Lok
and Lee [8] worked on two advanced ceramics viz. sailon
and Al203–Tic using wire-cut EDM which is evolving as
one of the promising methods for processing advanced
ceramics. The quality characteristics like material removal
rate and surface finish were compared under different cut-
ting conditions. Their results showed that the wire-cut EDM
process is a viable material-processing method for the ma-
chining of advanced ceramics; but work has to be carried
out to further study the ways and means of improving the
surface finish and surface integrity of the machined ceramic
to give a more reliable service life of components made of
advanced ceramics. Ozdemir and Ozek [9] investigated the
machinability of nodular cast iron by WEDM using different
parameters—machining voltage, current, wire speed, and
pulse duration. Results indicate that increase in surface
roughness and cutting rate clearly follows the trend indicat-
ed with increasing discharge energy as a result of an in-
crease of current and pulse-on time because the increased
discharge energy will produce larger and deeper discharge
craters. The variation of surface roughness and cutting rate
with machining parameters was mathematically modeled by
using the regression analysis method. Speeding and Wang
[10] developed a feed-forward backpropagation neural net-
work based on a central composite rotatable design to model
the machining process. Optimal parametric combinations
were selected for the process. Sanchez et al. [11] discussed
Int J Adv Manuf Technol (2013) 67:2269–2281
the influence of work thickness, corner radius, and number
of trim cuts on the accuracy of WEDM corner cutting. AISI
D2 tool steel as a work material and brass wire as a tool
were used. El Taweel [12] found the relationship of process
parameters in electrodischarge machining in which CK45
steel is used as a workpiece with tool electrode material such
as Al–Cu–Si–TiC composite. The central composite second-
order rotatable design is used for the design of experiments
and response surface methodology (RSM) was used for
experimental models. It was found that wire lag is respon-
sible for the back-wheel effect in corner cutting and devia-
tion was larger in case of test piece with smaller corner
radius. Puri and Bhattacharyya [13] made a model for the
white-layer depth with response surface methodology. A
white layer is considered a main problem on a workpiece
surface machined with WEDM. An experimental plan for
rotatable central composite design of second-order involv-
ing five variables with five levels has been employed to
carry out the experimental investigation and subsequently to
establish the mathematical model correlating the input pro-
cess parameters with the response.
Ramakrishnan and Karunamoorthy [14] optimized the
multiresponses viz., material removal rate, surface rough-
ness, and wire wear ratio with the help of Taguchi robust
design of experiments. The input process parameters were
pulse-on time, wire tension, delay time, wire feed speed, and
ignition current intensity. Rozenek et al. [15] experimentally
investigated the effect of machining parameters (discharge
current, pulse-on time, pulse-off time, and voltage) on the
machining feed rate and surface roughness during wire
electrical discharge machining of metal matrix composites
AlSi7Mg/SiC and AlSi7Mg/Al2O3. The machining feed rate
of WEDM cutting composites significantly depends on the
kind of reinforcement. The maximum cutting speed of
AlSi7Mg/SiC and AlSi7Mg/Al2O3 composites are approxi-
mately three and 6.5 times lower than the cutting speed of
aluminum alloy, respectively. Kuriakose and Shunmugam
[16] optimized the WEDM process for titanium alloys by
nondominated-sorting genetic algorithm and found that
there was no single optimal combination of cutting param-
eters, as their influences on the cutting velocity and the
surface finish are quite opposite. Pawade and Joshi [17]
optimized the multiresponses of Inconel 718 with a multi-
response optimization technique called Taguchi grey rela-
tional analysis technique or simply Grey relational analysis.
Natarajan et al. [18] used RSM for the optimization of
material removal rate and surface roughness. Central com-
posite design was used for the planning of experiments.
Control factors of the process were speed, feed rate, and
depth of cut. Kilickap et al. [19] made a mathematical model
of the surface roughness using RSM. The surface finish was
investigated at different machining condition for getting the
better surface finish. The effects of drilling parameters on
Int J Adv Manuf Technol (2013) 67:2269–2281 2271

the surface roughness were evaluated and optimum machin- process parameters and output responses namely cutting speed
ing conditions for minimizing the surface roughness were (CS) and dimensional deviation (DD). Design-Expert is used
determined using RSM and genetic algorithm. The given to analyze the experimental data and to build empirical models
model could be utilized to select the level of drilling param- by backward elimination. The mathematical model developed
eters. A remarkable saving in machining time and product is used to analyze and optimize the process parameters pro-
cost can be obtained by using this model. ducing optimal values of output response characteristics.
Datta and Mahapatra [20] presented the quadratic mathe-
matical model to represent the process behavior of WEDM
operation. Experiments have been conducted with six process 2 Experimental detail
parameters—discharge current, pulse duration, pulse frequen-
cy, wire speed, wire tension, and dielectric flow rate—to be In this research work, CS and DD are response character-
varied in three different levels. Data related to the process istics. These response characteristics are investigated under
responses viz., MRR, roughness value of the worked surface the varying conditions of input process parameters, which
(a measure of surface finish), and kerf have been measured for are Ton, Toff, servo gap voltage (SV), peak current (IP), and
each of the experimental runs. The results showed the estab- wire tension (WT). The experiments were performed on
lished mathematical models to highlight parametric influence Electronica make ELEKTRA Sprintcut 734 CNC Wire cut
on three selected process responses: material removal rate, machine. ELEKTRA Sprintcut 734 provides full freedom to
surface roughness value, and width of cut. Response surface the operator in choosing parameter values with in a wide
method has been found efficient for prediction of process range. A brass wire of 0.25 mm diameter is used as the tool
responses for various combinations of factor setting. Singh material. Deionized water is used as the dielectric, which
and Khanna [21] worked on cryogenic treated D-3 as a work- flush away the metal particle from the workpiece. The
piece and brass wire as a tool. Charmills Technologies Robofill workpiece shape is 5×5×18 mm of HSLA 100. The com-
290 was the machine tool used for research work. The planning position of HSLA 100 is shown in Table 1.
of experiments was carried by Taguchi technique and L27
orthogonal array was selected. The results show that cutting 2.1 Generation of part drawing for machining
rate decreases with increase in pulse width, time between two
pulses, and servo reference mean voltage. Cutting rate first The profile of the workpiece to be cut is shown in Fig. 1.
decreases and then increases with the increase in mechanical The wire entered the workpiece at point A (5, 0). The wire
tension. A lot of research has been carried out on WEDM with will move along a clockwise path along AB, BC, CD, and
various conductive materials. Out of that research, 22 % is on DA and will exit the workpiece from A (5, 0). Once the path
the optimizing the process variables, 33 % on WEDM devel- of the wire is established, it is processed to the ELAPT
opment, 45 % on monitoring and control the process [22]. software which generates the NC code for cutting. The 5-
In the present research study, WEDM of high-strength low- mm gap is kept between two successive cut due to the
alloy steel (HSLA 100) is considered. The material is selected stability of dimensional accuracy.
for the research study as it is conductive, having high strength,
corrosion-resistant and also wear-resistant alloy [23]. HSLA Table 1 Chemical
composition of Element Weight (%)
100 has low weight of the same volume as compared to other
HSLA 100
steel. Wire cut electric discharge machine always come along C 0.06
with operation manual and some of the operating data, which P 0.8
are conventionally used. If any other material (i.e., newer S 0.06
material or which is never machined on the WEDM) is to be Si 0.4
machined on this, then performance analysis must be carried Ni 1.6
out. Nowadays, industries are profit oriented, but people are Cr 0.62
quality oriented. Due to its high strength, corrosion, and wear Mo 0.37
resistant, this makes it favorable for automobile and die appli- Cu 1.13
cations. As no researcher carried a research on HSLA 100, Al 0.01
performance analysis is a must for this so that machining can Cb 0.03
be carried out at its optimum parameters in which quality and V 0.03
productivity can be balanced. Ti 0.02
The main objective of this research is to study the different Sn 0.03
process parameters of WEDM operations using response sur- Sb 0.025
face methodology, in particular central composite rotatable Fe Balance
design to develop an empirical relationship between different
2272
2.2 Monitoring of response characteristics
The output response parameters or response variable are CS
and DD. The average cutting speed (millimeters per minute) is
measured directly from the display of the machine tool. The
values of the cutting speed are noted down at distances of 2, 3,
and 4 mm from the starting of a cut in a particular direction so
that the cutting is stabilized. Because in the starting and at the
end of a cut the speed of cutting is slow, the offset of the wire
is set to zero. Dimensional deviation is measured from the
Mitutoyo’s digital micrometer having the least count of
0.001 mm and the deviation of the measured dimension is
calculated in percentage using the following expression:
observed value  actual value
Dimensional deviation ¼
actual value
 100
2.3 Experimental planning
RSM is a compilation of mathematical and statistical tech-
niques useful for the modeling and analysis of problems in
which output factors are influenced by several input param-
eters and the main aim is to optimize this output parameters
[24]. The procedure for RSM is as follows:
1. Preliminary experiments are performed.
2. Design the input parameters according to preliminary
experiments and output quality characteristics according
to requirement.
3. Then, select the experimental design.
4. Regression analysis is to be carried out.
5. Analysis of variance is to be found out.
6. If the model is significant
7. Optimal settings are to be found.
8. At these setting, confirm the predicted values of
experiment.
9. If model is not significant, then input parameters screening
are to be carried out and repeat the process from step 3.
Y-axis
C (0, 5) D (5, 5)
X-axis
A (5, 0)
B (0, 0)
Fig. 1 Work piece profile
Int J Adv Manuf Technol (2013) 67:2269–2281
Experimentation for the best is an old-age practice. Per-
form the experiment; repeat it for five to ten times for better
results. But in nonconventional machining, a lot of param-
eters are there. So the number of experiments becomes so
large that it is difficult to interpret. There is a need of design
of experiment so that the total number of experiments
becomes less. Polynomial response surface in RSM has
great advantages; it has a few disadvantages also. One such
disadvantage is that the polynomials are untrustworthy
when extrapolated beyond the experimental region. Another
important disadvantage of using second-order polynomial in
RSM is that the size of experiments becomes too large and
analysis becomes too complicated with more than three X
variables or with more than three levels. However, a well-
designed experimental plan can substantially reduce the
total number of experiments. Central composite designs
are one of those means. Proceeding a step ahead, central
composite rotatable designs of second order have been
found to be the most efficient tool in RSM to establish the
mathematical relation of the response surface using the
smallest possible number of experiments without losing its
accuracy [19]. The output response (y) can be modeled as
Eq. 1
X
k X
k X
y ¼ b0 þ b i xi þ bii x2i þ bij xi xj þ " ð1Þ
i¼1 i¼1 i<j
Where
x i , x j , and x k are input or independent process
parameters.
β0, βii, and βij are unknown parameters or regression
coefficients.
Ε is random error
The main limitation of WEDM is the loss in productivity
due to wire breakage. If the preliminary experiments before
the actual experimentation are done carefully, then a range
of process parameters obtained, where breakage of wire did
not take place. In the present research work, the following
five process parameters, i.e., Ton, Toff, SV, IP, and WT are
chosen as input variables (xi). There are other process
parameters which effect less significantly on the measures
of response quality characteristics; these are kept constant
and called WEDM machining conditions. Table 2 shows the
different process parameters, their coded symbols, and lev-
els. Table 3 shows WEDM machining conditions.
According to central composite rotatable design, with
five process parameters at half fraction, a total of 32 experi-
ments need to be performed as illustrated in Table 4. The
half fraction is selected to reduce the number of experi-
ments. Each time the experiment was performed, a particu-
lar set of process parameter was chosen and workpiece was
cut as per Fig. 1 (discussed earlier in Section 2.1).
Int J Adv Manuf Technol (2013) 67:2269–2281 2273

Table 2 Different levels of Process parameters with coded form and represent data in the experimental domain at which points are
units
not included in the regression variations in the model that
Process parameters Coded Units Levels cannot be accounted for by random error. If there is a significant
factors lack of fit, as indicated by a low probability value, the response
−2 −1 0 1 2 predictor is discarded [25]. The lack of fit is nonsignificant and
its value is 0.557. From Table 5, it is found that R2 of the model
Pulse on time (Ton) A μs 108 111 114 117 120
is 0.9968, which is very close to 1. The meaning behind this is
Pulse off time (Toff) B μs 29 36 43 50 57
that 99.68 % variation can be explained by this model and only
Spark gap voltage (SV) C V 20 30 40 50 60
0.32 % of total variation cannot be explained, which is an
Peak current (IP) D A 90 120 150 180 210
indication of good accuracy. The predicted R2 is in logical
Wire tension (WT) E g 4 6 8 10 12
concurrence with the adjusted R2 of 0.9935. Figure 2 shows
the normal probability plot of residuals for CS. Most of the
3 Results and discussion residuals are found around the straight line, which means that
errors are normally distributed.
There are 32 experiments in total carried out according to Adequate precision compares the significant factors to the
the design of experiments. The average values of CS (milli- nonsignificant factors, i.e., signal to noise ratio. According to
meters per minute) and DD (%) are shown in Table 4. For the results obtained from the software, ratio greater than 4 is
analysis of data, checking the goodness of fit of model is desirable. In this, the adequate precision is 67.439, so the
required. The model adequacy checking includes test for signal to noise ratio is significant. By applying multiple re-
significance of regression model, test for significance on gression analysis on the experimental data, the empirical
model coefficients, and lack of fit test [26]. For this purpose, relation in terms of coded factors is obtained as follows:
ANOVA is performed. Final equation in terms of coded factors:

3.1 Analysis of cutting speed Cutting speed ¼ þ1:14 þ 0:24  A  0:26  B  0:14  C
þ 0:077  D  9:583E  003  E  0:029  A2
According to the fit summary obtained from analysis, it is
found that quadratic model is statistically significant for CS.  0:062  B2  0:033  C2  0:084  A  B
The results of the quadratic model for CS in the form of þ 0:048  A  D  0:079  A  E
ANOVA are presented in Table 5. If the F value is more þ 0:068  B  C  0:027  B  E
corresponding, p value must be less corresponding resulting
þ 0:021  C  D þ 0:41  C  E
in a more significant corresponding coefficient. Nonsignificant
terms are removed by backward elimination for the fitting of þ 0:018  D  E
CS in the model. Alpha out value is taken at 0.05 (i.e., 95 % ð2Þ
confidence level). When quadratic model with backward elim- Final equation in terms of actual factors:
ination is selected, the model is not hierarchical so the wire
tension (E in coded form) is hierarchically added. A model is Cutting speed ¼ 71:66013 þ 1:02336  Ton
said to be hierarchical if the presence of higher-order terms þ 0:50630  Toff  0:056081  SV
(such as interaction and second-order terms) requires the inclu-
sion of all lower-order terms contained within those of higher  0:063556  IP þ 1:45932  WT
order. It is found from Table 5 that F value of the model is  3:26923E  003  T2on  1:26374E
296.13 and related p value is <0.0001, results of a significant
model. The lack of fit is a measure of the failure of the model to  003  T2off  3:31731E
 004  SV2  4:01786E  003  Ton
Table 3 WEDM machining conditions
 Toff þ 5:34722E  004  Ton  IP
Work piece material HSLA 100
Tool material Brass wire, ø 0.25 mm  0:013229  Ton  WT þ 9:73214E
Shape and size of work piece Square, 5 mm×5 mm×18 mm  004  Toff  SV  1:91964E  003
Dielectric conductivity 15–20 mho
 Toff  WT þ 6:87500E  005  SV
Servo feed 2,050 machine units
Dielectric pressure 7 Kg/cm2  IP þ 2:03125E  003  SV  WT
Dielectric temperature 24 °C
þ 3:02083E  004  IP  WT
Wire feed 8 machine units
ð3Þ
2274 Int J Adv Manuf Technol (2013) 67:2269–2281

Table 4 Design of experiments

and results for wire EDM output Standard order Run order Process parameters Responses
response
A: Ton B: Toff C:SV D:IP E:WT CS DD
(μs) (μs) (V) (A) (g) (mm/min) (%)

17 1 108 43 40 150 8 0.53 0.613

30 2 114 43 40 150 8 1.17 0.393
27 3 114 43 40 150 8 1.2 0.347
23 4 114 43 40 90 8 0.98 0.427
11 5 111 50 30 180 10 0.71 0.6
1 6 111 36 30 120 10 1.19 0.633
25 7 114 43 40 150 4 1.12 0.287
18 8 120 43 40 150 8 1.51 0.307
4 9 117 50 30 120 10 0.68 0.527
32 10 114 43 40 150 8 1.13 0.347
14 11 117 36 50 180 6 1.53 0.127
2 12 117 36 30 120 6 1.84 0.493
13 13 111 36 50 180 10 0.94 0.433
12 14 117 50 30 180 6 1.25 0.327
6 15 117 36 50 120 10 1.2 0.227
31 16 114 43 40 150 8 1.13 0.36
7 17 111 50 50 120 10 0.53 0.367
10 18 117 36 30 180 10 1.81 0.433
22 19 114 43 60 150 8 0.71 0.193
9 20 111 36 30 180 6 1.09 0.54
19 21 114 29 40 150 8 1.4 0.4
16 22 117 50 50 180 10 0.93 0.153
5 23 111 36 50 120 6 0.6 0.407
21 24 114 43 20 150 8 1.3 0.807
26 25 114 43 40 150 12 1.14 0.44
29 26 114 43 40 150 8 1.13 0.38
20 27 114 57 40 150 8 0.38 0.333
8 28 117 50 50 120 6 0.77 0.167
24 29 114 43 40 210 8 1.26 0.253
28 30 114 43 40 150 8 1.13 0.327
3 31 111 50 30 120 6 0.67 0.513
15 32 111 50 50 180 6 0.51 0.36

From Eq. 2, it is concluded that the main effects of Ton,
Toff, SV, IP, two-factor interaction between Ton and Toff, Ton
and IP, Ton and WT, Toff and SV, and SV and WT have
significant effects on CS.
3.1.1 Effect of process parameters on cutting speed
The effect of two control factors or process parameters on
the response variables are called the interaction effect. For
the interaction plot, the two parameters vary keeping other
three process parameteres at the central value and observe
the effect on the response characteristics. This plot is called
the three-dimensional surface plot (i.e., 3D surface plot). So
the significant interactions are shown in Figs. 3, 4, 5, 6, and
7. The interaction effect (combined effect) of Ton and Toff on
CS (as shown in Fig. 3) shows that CS goes to a maximum
value 1.629 mm/min at a high value of Ton (117) and a low
value of Toff (36), while it reaches at a minimum level,
where Ton is minimum (110) and Toff is maximum (50). This
is due to the fact that higher Ton and lower Toff means that
discharge will take place for a long time, long time of
discharge means a higher value of discharge energy. A
higher value of discharge energy creates violent sparks
between the workpiece and moving electrode, these sparks
causes a faster erosion of material and a faster cutting speed
is observed. The 3D interaction plot of Ton and IP ( Fig. 4)
shows that CS attains a maximum value of 1.473 mm/min at
a higher value of Ton (117) and higher IP value (180).
Int J Adv Manuf Technol (2013) 67:2269–2281 2275

Table 5 ANOVA for response

surface of reduced quadratic ANOVA table [partial sum of squares]
model of cutting speed
Source Sum of squares DF Mean square F value Prob>F

Model 4.12 16 0.26 296.13 <0.0001 Significant

A 1.37 1 1.37 1571.57 <0.0001
B 1.6 1 1.6 1834.03 <0.0001
C 0.48 1 0.48 556.59 <0.0001
D 0.14 1 0.14 163.82 <0.0001
E 2.20E-03 1 2.20E-03 2.53 0.1324
A2 0.026 1 0.026 29.55 <0.0001
B2 0.11 1 0.11 130.89 <0.0001
C2 0.033 1 0.033 37.56 <0.0001
AB 0.11 1 0.11 130.85 <0.0001
AD 0.037 1 0.037 42.57 <0.0001
AE 0.1 1 0.1 115.8 <0.0001
BC 0.074 1 0.074 85.3 <0.0001
BE 0.012 1 0.012 13.28 0.0024
CD 6.81E-03 1 6.81E-03 7.82 0.0136
CE 0.026 1 0.026 30.33 <0.0001
DE 5.26E-03 1 5.26E-03 6.04 0.0267
Residual 0.013 15 8.71E-04
Lack of fit 8.57E-03 10 8.57E-04 0.96 0.5571 Not significant
Pure error 4.48E-03 5 8.97E-04
Cor total 4.14 31
SD 0.03 R2 0.9968
Mean 1.05 Adj R2 0.9935
C.V. 2.82 Pred R2 0.9796
Press 0.084 Adeq precision 67.439

Normal Plot of Residuals

99

1.62902
95
1.38069
Normal % Probability

90

80 1.13236
70
0.884022
CS

50
0.635689
30
20

10

50.00
1 117.00
46.50
115.50
43.00
114.00

-1.76 -0.75 0.25 1.25 2.26

B: Toff 39.50 112.50
A: T on
Studentized Residuals 36.00 111.00

Fig. 2 Normal probability plot of residuals for CS Fig. 3 Interaction effect of Ton and Toff
2276 Int J Adv Manuf Technol (2013) 67:2269–2281

1.51236
1.47386
1.31236
1.31595
1.11236
1.15803
0.912356

CS
1.00011 0.712356
CS

0.842196

50.00
50.00
45.00
180.00 46.50
117.00 40.00
43.00
165.00
115.50 C: SV 35.00 39.50
B: Toff
150.00
114.00 30.00 36.00

D: IP 135.00 112.50
A: T on Fig. 6 Interaction of Toff and SV
120.00 111.00

Fig. 4 Interaction effect of Ton and IP
The effect of Ton is already explained (i.e., higer Ton is
essential for better CS). If IP is more, then it means that
discharge energy is more, which results for a better cutting
speed. But the sensitivity of the peak current setting on the
cutting performance is stronger than that of the pulse on
time. While the peak current setting is too high, wire break-
age may occur frequently [26].
Figure 5 shows the 3D inteaction plot of Ton and WT on
CS. Higher value of Ton (117) and lower value of WT (6)
results in a higher value of CS (1.437 mm/min). While CS
gains a minimum decrement at lower value of Ton (111) and
lower value of WT (6). At low-wire tension, the wire near the
cutting zone may become slack and may produce unintention-
al wire deflection from its path. Due to this, the location of
impingement of spark may become uneven, i.e., each succeed-
ing spark may be cutting a portion of workpiece already cut by
the proceeding spark [25]. Figure 6 reveals that a lower value
of Toff (36) and SV (30) favors a higher CS (1.512 mm/min).
CS (0.71 mm/min) goes down at a higher value of Toff (50)
and SV (50). This is due to the fact that the higher the SV, the
higher will be the discharge waiting time. To obtain the higher
discharge wait time, machining speed needs to be slowed
down. So lower value of SV favors productivity. While at
the same time, lower value of Toff means there will be more
time for which current is on, i.e., more number of discharges

1.43761

1.29845
1.27855
1.20709
1.11949
1.11574
0.960425
CS

1.02438
CS

0.801362
0.933029

10.00
10.00
117.00
50.00
9.00
9.00
115.50 45.00
8.00 8.00
114.00 40.00
E: WT 7.00 112.50 E: WT 7.00 35.00
A: Ton C: SV
6.00 111.00 6.00 30.00

Fig. 5 Interaction of Ton and WT Fig. 7 Interaction of SV and WT

Int J Adv Manuf Technol (2013) 67:2269–2281 2277

per second which means that metal erosion will be more, Final equation in terms of coded factors:
hence faster cutting speed results. By combining these two
effects, the CS will attain a maximum value. A lower value of Dimentional deviation ¼ þ0:35  0:084  A  0:017
SV and WT favors a higer CS (Fig. 7). The effects of SV and  B  0:13  C  0:030
WT on CS are already cited in the text.
 D þ 0:031  E þ 0:022
3.2 Analysis of dimensional deviation
 A2 þ 0:032  C2  0:024
It is clear from Table 6 that the model is significant with an F  A  C  0:024  A  D ð4Þ
value of 61.75 and an I value of <0.0001. It is an old-age fact
that if the F value is large, the parameter is more significant. Final equation in terms of actual factors:
From Table 6, it is found that Ton and SV are the most Dimension deviation ¼ þ28:19385  0:51293  Ton
significant. Quadratic model is statically significant for the
analysis. The value of R2 and adjusted R2 has a close relation-  2:45833E  003  Toff
ship. The value of R2 is 0.9619; 96.19 % of variation can be þ 0:053585  SV þ 0:029653
explained by the model and only 3.81 % variation cannot be
 IP þ 0:015521  WT
explained. So the model provides a good accuracy. Lack of fit
of the model is 0.1713 and is not significant. Signal to noise þ 2:44544E  003  T2on
ratio (i.e., adequate precision) of the model is 32.539, which is
þ 3:20089E  004  SV2
desirable. Figure 8 shows the normal probability plot of resid-
uals for DD. From Fig. 8, it is evident that all the residuals are  8:06250E  004  Ton  SV
clustered on the straight line, implying that errors are normally  2:68750E  004  Ton  IP
distributed. Nonsignificant terms are eliminated by backward
ð5Þ
elimination with the alpha-out value of 0.05 (i.e., 95 % con-
fidence level) while abiding by the hierarchy principle. The
main effects of Ton, Toff, SV, IP, and WT, and interaction 3.2.1 Effect of control factors on dimensional deviation
effects between Ton and SV, Ton and IP are found to be
statistically significant for the analysis. The following re- The quality of the output should be better when the obtained
sponse surface equation in coded factors is obtained. dimensions of the object is nearer to what is required.

Table 6 ANOVA for Response

Surface of Quadratic Analysis of variance table [partial sum of squares]
Model of DD
Source Sum of squares DF Mean square F value Prob>F

Model 0.67 9 0.074 61.75 <0.0001 Significant

A 0.17 1 0.17 139.94 <0.0001
B 7.11E-03 1 7.11E-03 5.9 0.0237
C 0.39 1 0.39 322.54 <0.0001
D 0.021 1 0.021 17.39 0.0004
E 0.023 1 0.023 19.21 0.0002
A2 0.014 1 0.014 12.01 0.0022
C2 0.031 1 0.031 25.41 <0.0001
AC 9.36E-03 1 9.36E-03 7.77 0.0107
AD 9.36E-03 1 9.36E-03 7.77 0.0107
Residual 0.026 22 1.20E-03
Lack of fit 0.024 17 1.39E-03 2.38 0.1713 Not significant
Pure error 2.91E-03 5 5.82E-04
Cor total 0.7 31
SD 0.035 R2 0.9619
Mean 0.39 Adj R2 0.9463
C.V. 8.87 Pred R2 0.8848
PRESS 0.08 Adeq precision 32.539
2278 Int J Adv Manuf Technol (2013) 67:2269–2281

Norm al Plot of Res iduals occurrence. Thus, dimensional deviation decreases (attains
best value as minimum is better). With the increase in SV,
the cutting rate decreases. Due to decrease in cutting rate,
99 erosion process will be slowed down. If a slower erosion
process takes place, then a good dimensional accuracy is
Normal % Probability

95
obtained; so after the combination of the above two facts,
90
DD goes to its lowest value. It can be seen from the inter-
80
action plot of Ton and IP (Fig. 10) that a higher value of Ton
70
(117) and IP (180) favors DD and attains a value of 0.232 %.
50 The effect of Ton on DD is already cited above, while the
30 dimensional deviation decreases with increase in the peak
20 current. The density of spark discharges would also be
10 changed depending on the peak current. This will have an
5 impact on the precision and accuracy of the workpiece when
all the other control factors are at the central level. The effect
1
of this interaction is very weak as apparent from a smaller F
value in Table 6.

-1.62 -0.41
Studentized Residuals
Fig. 8 Normal probability plot of residuals for DD
During the analysis, it is considered that for DD, minimum
is the better, i.e., output will deviate a small amount from the
requisite. The 3D interaction surface for DD due to the
interaction effect of Ton and SV is shown in Fig. 9.
With increase in Ton from 111 to 117 and SV from 30 to
50, DD follows a decreasing trend attaining the lowest value
of 0.169. A probable reason for it may be that with increase
in pulse-on time, discharge energy increases. During every
individual spark discharge, the wire experiences an impact,
which acts in the reverse direction of the discharge
0.79 2.00 3.20 3.3 Multiresponse optimization of process parameters
Multiresponse optimization is a process of maintaining a
balance between two or more than two responses. The main
objective of this research is to maintain a balance between
the productivity and quality. In this, productivity means
cutting speed; as the cutting speed is large, a number of
product at a given time will be more. Productivity is useful
for the mass production industries. Quality means dimen-
sional deviation, which is very useful for precision industry.
Dimensional deviation is required for batch production area,
where dimensional accuracy is more important than produc-
tivity. These two are opposite in nature. If cutting speed
increases, then dimensional deviation decreases and the
reverse is also true. Derringer and Suich [27] express a
multiresponse technique called desirability. It is very useful

0.591598
0.461923
0.486098
0.405256
0.380598
0.348589
0.275098
DD

0.291923
DD

0.169598
0.235256

50.00
180.00
117.00
117.00
45.00 165.00
115.50 115.50
40.00 150.00
114.00 114.00
C: SV 35.00 112.50 D: IP 135.00 112.50
A: Ton A: Ton
30.00 111.00 120.00 111.00

Fig. 9 Interaction effect of Ton and SV Fig. 10 Interaction effect of Ton and IP
Int J Adv Manuf Technol (2013) 67:2269–2281 2279

Table 7 Control factor setting with high value of Desirability

Importance of both CS as well as DD kept same i.e. 3

Sr. no. CS DD Control factors Predicted response variable Desirability

W1 W2 Ton Toff SV IP WT CS DD

1 0.7 0.3 117 36.02 38.17 180 6 1.83857 0.257671 0.968 Selected
2 0.7 0.3 117 36 38.08 180 6.05 1.83999 0.25978 0.968
3 0.7 0.3 116.99 36.14 37.86 180 6.01 1.83999 0.262685 0.967
1 0.5 0.5 116.97 36 45.36 179.93 6 1.66133 0.16218 0.957 Selected
2 0.5 0.5 117 36.08 46.5 180 6.08 1.63197 0.144832 0.956
3 0.5 0.5 116.99 36 41.14 179.73 6 1.76948 0.21287 0.955
1 0.3 0.7 116.99 36 47.92 179.99 6 1.59406 0.129328 0.972 Selected
2 0.3 0.7 117 36 47.9 180 6.13 1.59466 0.130941 0.971
3 0.3 0.7 117 36.11 48.41 179.41 6.17 1.57578 0.127003 0.97

for multiresponse optimization during research or industries.
This approach makes use of an objective function, D(X),
called the desirability function and converted a projected
response into a scale-free value (di) called desirability. Com-
posite desirability is the weighted geometric mean of the
individual desirability for the responses. The factor settings
with maximum total desirability are considered to be the
optimal parameter conditions. The optimization is carried by
following steps [28]
– Calculating the individual desirability (d) for each
response
– combining the individual desirability to obtain the com-
posite desirability (D)
– maximizing the composite desirability and identifying
the optimal settings of the control factors
The simultaneous objective function is a geometric mean
of all transformed responses:
1 lution provided by this expressing desirability.
D ¼ ðd1  d2  d3  :::::::::::::::::  dn Þ n
! 1n
Yn
¼ di
i¼1
Where, n is the number of responses in the measure. If any
of the responses or factors falls outside the desirability
range, the overall function becomes zero. Equation 6 can
be modified as Eq. 7 by incorporating the concept of assign-
ing different weights to responses can be extended to
 1
D ¼ d1w1  d2w2  . . . . . . . . . . . .  dnwn n ð7Þ
to reflect the possible difference in the importance of differ-
ent responses, where the weight satisfies 0<wi <1 and
X
n
wi ¼ 1 ð8Þ
i¼1
The Design Expert 6.0 software, having response surface
methodology, is used to optimize the machining parameters.
As shown in Table 7, experiments are performed by varying
the weight of response variables. Predicted response varia-
bles obtained from experiments define weight for both re-
sponse; and after getting values from weight methods,
confirmation experiments are performed at the optimal so-
Importance of responses can be varied from 1 to 5, i.e.,
least desirable to most desirable. Here, importance of
ð6Þ responses is kept constant and is equal to 3. Table 7 shows
optimal setting of the control factors by varying the weights
of responses. Three settings of weights are to be investigated
and the optimal setting having higher desirability is selected
for the confirmation experiment as shown in Table 8.

Table 8 Confirmation experiments and their comparison with the results

Weights Process parameters CS (mm/min) DD (%)

Sr. no w1 w2 Ton Toff SV IP WT Pred. Actual Error (%) Pred. Actual Error (%)

1 0.7 0.3 117 36 38 180 6 1.838 1.937 5.11 0.257 0.2341 −9.78
2 0.3 0.7 117 36 48 180 6 1.59 1.463 −8.68 0.129 0.1315 1.9
3 0.5 0.5 117 36 45 180 6 1.661 1.784 6.89 0.162 0.1781 9.04
2280 Int J Adv Manuf Technol (2013) 67:2269–2281

This is a long-age problem to optimize the two 4 Conclusions

response parameters, which are opposite in nature.
Weighing method is used to distinguish this. In this In this paper, effect of process parameters on cutting speed
method, more weight is given to that response which and dimensional deviations are investigated. From the anal-
is more desired for an industry. If one industry is ysis, it is concluded that:
interested only in production at the verge of its quality,
(a) For both CS and DD, Ton is the most significant process
then more weight is given to CS and less for DD. If
parameter.
any other industry is interested only in precision things
(b) For cutting speed, the main effects of Toff and Ton are
(better quality), more weight is placed for DD and less
the most significant process parameters. SV, IP, qua-
for CS. There are a lot of industries in today’s scenario
dratic function of Toff, two-factor interactions of Ton
which maintain a balance in productivity and quality; so
and Toff, and Ton and WT play a significant role for
equal weight is given for CS and DD. Table 8 give
response variable. Quadratic function of Ton and SV,
results of three confirmation experiments of multires-
interaction effects of Toff and SV, Ton and IP, and SV
ponse characteristics. It gives the optimized process
and WT are nonsignificant for cutting speed. Wire
parameters setting along with predicted CS and DD
tension has negligible effect on cutting speed. Wire
values. At the optimized setting, confirmation experi-
tension as a main effect shows little effect on cutting
ments give the results on data about the weighting
speed, but is included in the regression equation for
factors w1 (assigned to CS) and w2 (assigned to DD).
surface roughness to obey the principle of hierarchy
First analysis is performed keeping a higher weight for
because its interaction with Ton shows a considerable
CS (0.7) and a lower weight for DD (0.3). This exper-
effect on cutting speed.
iment is useful in those industries, where the production
(c) For dimensional deviation, the main effect of SV and
is the dominant factor. The predicted response for CS
Ton plays the most significant role. The main effect of
and DD are 1.883 mm/min and 0.257 %. In the second
IP and WT, and quadratic function of SV and IP,
experiment, CS assigned a weight of 0.3 and DD set a
influence DD considerably. Two-factor interaction of
weight of 0.7. This experiment plays an important role
Ton and SV, and Ton and IP have less influence on DD.
in precision-type industries for the batch production
(d) The predicted values match the experimental values
only. In some of the applications, production do not
reasonably well, with R2 of 0.9968 for CS and R2 of
matter much than quality like aerospace industries. After
0.9619 for DD.
setting the weights, the optimized process parameters
(e) Weight plays a considerable role in the multiresponse
are obtained along predicted CS (1.59 mm/min) and
optimization. This is clear from the range of predicted
DD (0.129 %). From these two analyses, it is found
values which varies from 1.59 to 1.838 mm/min for
that DD reduces at the cost of CS. In the third analysis,
cutting speed and 0.129 to 0.257 % for dimensional
both CS and DD assigned the same weight of 0.5. This
deviation.
experiment is performed only for today’s scenario keep-
(f) For both the response parameters, the predicted values
ing the balance between production and quality. Today,
of the responses are in close agreement with experi-
an industrialist wants to earn maximum profit (maxi-
mental results.
mum production means more profit) while customer
wants a good quality (less dimensional deviation). Third
experiment is performed for obtaining optimized process
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