One of the non-conventional machining processes widely used in the industry is the wire electrical discharge machining (WEDM). This process has many advantages, like the great precision and quality that can be achieved. As well as other manufacturing operations, the success of the process relies on a correct selection of the cutting parameters. The present paper outlines an experimental study to optimize the machining time and the surface roughness in WEDM of AISI D2 tool steel during roughing machining. The Taguchi methodology is used to evaluate the effects and contributions of the pulse-on time, pulse-off time, servo voltage, and wire speed, on the response variables. The desirability method is employed to define a set of cutting parameters that allows reducing both machining time and surface roughness at the same time. The pulse-on time is the most significant factor for reducing the machining time, followed by the servo voltage, the pulse-off time and the wire speed. For surface roughness, the pulse-off time is the factor with the greatest influence over the response variable. The results obtained show that the machining time is reduced by 4.65%, and the surface roughness is diminished by 4.60% when compared with the initial values that are commonly used in the machining of AISI D2 tool steel. Therefore, greater production rates can be achieved without compromising the quality of the machined parts.
Multi-pass friction stirred clad welding of dissimilar joined AA6061 aluminium alloy and brass