International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 2, March-April 2016, pp. 307320, Article ID: IJMET_07_02_033

Available online at
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=7&IType=2
Journal Impact Factor (2016): 9.2286 (Calculated by GISI) www.jifactor.com
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
IAEME Publication

OPTIMIZATIONS OF MACHINING
PARAMETER IN WIRE EDM FOR 316L
STAINLESS STEEL BY USING TAGUCHI
METHOD, ANOVA, AND GREY ANALYSIS
Manish Saini, Rahul Sharma, Abhinav, Gurupreet Singh, Prabhat Mangla
Student, Mechanical Department GNI-Mullana,
Kurukshetra University, Kurukshetra, Haryana, India
Er. Amit Sethi
Asist. Professor, Mechanical Deptt, GNIMullana
Kurukshetra University, Kurukshetra, Haryana, India
ABSTRACT
WEDM is one of the non-traditional method used for the machining
complex shape structure and components made up of hard material like
composites and HSS. This is an experimental investigation of wire electrodischarge machining (WEDM) of 316L SS. The outstanding characteristics of
stainless steel 316L such as their compatibility and noticeable physical,
mechanical and biological performance has led to increased application of
them in various industries especially in biomedical industries over the last 50
years.316L SS is used extensively for weldments where its immunity to carbide
precipitation due to welding assures optimal corrosion resistance. There are
some difficulties in machining of stainless steel by conventional machining.
On the other hand, unconventional machining process especially Wire
electrical discharge machining (WEDM) are more appropriate techniques for
machining difficult to machine materials such as stainless steel. Electrical
conductive materials are cut by wire EDM that uses a wire as electrode in an
electro-thermal mechanism. The machines also specialize in cutting complex
contours or fragile geometries that would be difficult to be produced using
conventional cutting methods. The focus of this paper is on machining of
stainless steel with WEDM because of the above mentioned features of WEDM
and its suitability for machining stainless steel. In this study the effect of nine
parameters including five controlled such as servo voltage(SV), peak
current(Ip), pulse-on time(Ton), pulse-off time (Toff), wire feed (WF) and four
remains fixed such as water pressure (WP), wire tension(WT), servo
feed(SF),voltage potential (VP) on process performance parameters such as
cutting speed and surface roughness are investigated. A Taguchi L 16 design of

http://www.iaeme.com/IJMET/index.asp

307

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi
experiment (DOE) is applied to determine the effect of significant parameters
on WEDM performance. The optimal parameters were obtained as (A1 B4 C4
D1 E2) for cutting rate and (A4 B1 C1 D4 E2) for surface roughness.
Optimum predicted values for cutting rate and surface roughness are
2.2009mm/min and = 0.5598 m respectively. By using ANOVA three
parameters namely pulse-on time, pulse-off time and servo voltage were found
the most significant affecting the cutting rate and surface roughness under
99% confidence level. By grey analysis, the optimum machining parameters
setting can be obtained for considering maximum cutting speed and minimum
surface roughness simultaneously. Thus the optimal set of process parameters
is (A2 B2 C4 D4 E2).
Key words: 316l Ss, Biomaterials, Cutting Speed, Surface Roughness,
Taguchi, Anova, Grey Analysis
Cite this Article Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh,
Prabhat Mangla and Er. Amit Sethi. Optimizations of Machining Parameter In
Wire EDM For 316l Stainless Steel by Using Taguchi Method, Anova, and
Grey Analysis. International Journal of Mechanical Engineering and
Technology, 7(2), 2016, pp. 307320.
http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType=2

1. INTRODUCTION
Wire electrical discharge machining (WEDM) is an important technology, which
demands high-speed cutting and high-precision machining to realize productivity and
improved accuracy. Wire electrical discharge machining (WEDM) is an indispensable
machining technique for producing complicated cut outs through difficult to machine
metals without using high cost grinding or expensive formed tools [1]. WEDM is an
extremely potential electro thermal process for hard metal alloy to get the high
precision. When the servo voltage is increased, there will be spark produced and
temperature will be high of 10,000 of degrees. Due to this high temperature metal will
be removed from the work piece. Material is eroded from the work piece (Anode) and
wire tool electrode (Cathode) separated by deionised water such as dielectric fluid and
continuously flushes away the machining debris. The movement of the wire is
controlled by CNC technology. WEDM has greatly altered the tooling and
manufacturing industry, resulting in dramatic improvements in accuracy, quality
productivity and profit. Over the years, WEDM process has remained as a competitive
economical machining option fulfilling the demanding matching requirements
imposed by the short product development cycle and the growing cost pressure.
Stainless steels have been widely used in various industries because of their good
corrosion resistance and mechanical properties. Among of them, austenitic stainless
steel 304 is the commonest type of stainless steels. However, due to the low hardness,
poor wear resistance of stainless steel, sensitive to pitting corrosion and stress
corrosion cracking in chloride solution, [24] the strength of the stainless steel can be
reduced, which limits its application in industrial production. Therefore, how to
improve the corrosion resistance of stainless steel in chloride ion solution and the
wear resistance of stainless steel has been a problem. In this case, it came into being
and developed rapidly that the ceramic films were used to coat on the stainless steel
surface [57]. Stainless steel materials are widely used for multiple applications
because of their good mechanical properties and very good corrosion resistance in a
number of environments [8]. stainless steel 316L is having a good resistance to creep

http://www.iaeme.com/IJMET/index.asp

308

editor@iaeme.com

Optimizations of Machining Parameter In Wire EDM For 316l Stainless Steel by Using
Taguchi Method, Anova, and Grey Analysis

and fatigue, excellent corrosion resistance and biocompatibility, excellent weldability

and easier to machine therefore 316L stainless steel is having more applications like
oil & petroleum , refining equipment, food processing equipment, pharmaceutical
processing equipment, architectural, biomedical .stainless steel constitute prominent
class of valuable iron alloys. They are used in variety of applications when enhanced
properties like corrosion and oxidation resistance. Coupled to good mechanical
characteristics are required. The stainless steel grades currently manufactured by
sintering correspond generally to the grade manufactured with other technology.316L
austenitic stainless steel is now a days widely used engineering material due to its
excellent oxidation resistance and good formability. On refining grains of 316L
stainless steel several technique have been used in which coarse grains are refined via
plastic deformation or subsequent re-crystallization mechanical milling, cold rolling,
severe plastic deformation. 316L were mechanically milled and sintered at 1173k.
316L tends to work harden if machined too quickly for this reason low speed and
constant feed rates are recommended. Additionally, WEDM is able to cut metals as
thin as 0.004.the wire of WEDM unit emits sparks on all sides, which means the cut
must be thicker than the wire itself. Wire electrode is generally made of copper, brass
or tungsten of diameter 0.05mm to 0.3mm, which is capable to achieve very small
corner radii. Thus WEDM has evolved from a simple means of making tools and dies
to the best alternatives of producing micro-scale parts with the highest degree of
dimensional accuracy and surface finish quality [9-11].

Figure 1 Schematic diagram of working of Wire-EDM

2. MATERIAL SELECTION
Selection of material depends upon the desire weld ability qualities which must rely
on basic properties of the material, such as strength, corrosion or erosion resistance,
ductility, and toughness. The properties of the various metallurgical characteristics
associated with the thermal cycles encountered in the welding operation must also be
included in the design process. The specimens of 20mm x 10mm x10mm are
prepared. The Stainless steel 316 L alloy was been used in this study. Chemical
composition of work piece is very much essential for selecting the type of process and

http://www.iaeme.com/IJMET/index.asp

309

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi
their controllable variables. Table 1 indicates the chemical composition of Stainless
steel 316L.
Table 1 Chemical composition of Stainless steel 316L. (Wt.%)
C
%

Mn
%

P
%

S
%

Si
%

Cu
%

Ni
%

Cr
%

V
%

Mo
%

Fe
%

0.0306

1.191

0.0305

0.0026

0.2062

0.1041

10.34

16.73

0.0433

2.015

Balance

3. METHOD OF EXPERIMENT
Taguchi method
Taguchi method is a powerful tool for the design of high quality systems. It provides
simple, efficient and systematic approach to optimize designs for performance, quality
and cost. Optimization of process parameters is the key step in Taguchi method to
achieving high quality without increasing cost. This is because optimization of
process parameters can improve quality characteristics and optimal process
parameters obtained from Taguchi method are insensitive to the variation of
environmental conditions and other noise factors. Classical process parameters design
is complex and not an easy task. To solve this task the Taguchi method uses a special
design of orthogonal arrays to study the entire process parameter space with a small
number of experiments only.

Anova
The analysis of variance (ANOVA) of raw data and S/N data were performed to
determine the significant and insignificant variables and to show their effects on the
response characteristic. Then, the response curves (main effect) were plotted for raw
data and S/N data in order to examine the parametric effects on the response
characteristics. Finally, the optimal values of significant process parameters in terms
of mean response characteristics are defined based on analyzing the ANOVA table
and response curves.

Grey relational analysis (GRA)

The Grey Theory was introduced by Dr. Deng J.L. (1982) which includes Grey
relational analysis, Grey modeling prediction and decision making of a systems
including incomplete information, multi-input and discrete and poor data information
where as partial information is to be known and partial information is unknown. A
grey relational grade is obtained to evaluate the multiple performance characteristics.
In GRA optimization of complicated multiple performance characteristics can be
converted into optimization of a single grey relational grade.

Experiment setup
The mechanism of metal removal in wire electrical discharge machining mainly
involves the removal of material due to melting and vaporization caused by the
electric spark discharge generated by a pulsating direct current power supply between
the electrodes. In this mechanism, negative electrode is a continuously moving wire
and the positive electrode is the work piece. The sparks will generate between two
closely spaced electrodes. Different numbers of experiments were performed to study

http://www.iaeme.com/IJMET/index.asp

310

editor@iaeme.com

Optimizations of Machining Parameter In Wire EDM For 316l Stainless Steel by Using
Taguchi Method, Anova, and Grey Analysis

the effects of the various machining parameters of wire electric discharge machining.
The studies have been undertaken to investigate the effect of peak current (Ip),wire
feed (Wf), servo voltage (SV), pulse on time (Ton) and pulse off time (Toff).The
material of the wire is zinc coated brass wire having a diameter of 0.25mm .For the
calculation of the cutting speed (CS) and surface roughness(SR) we cut the small
pieces of the material 316L stainless steel of dimension 20mm x 10mm x10mm to
measure and surface roughness with surface roughness tester SRT-8210 and wire
EDM machine calculates the cutting speed, and the value is displayed on the output
screen of the CNC interface.
Table 2 Process parameters and their levels
Factor

Process Parameters

Level 1

Level 2

Level 3

Level 4

A
B
C
D
E

Servo voltage (SV)

Peak current (Ip)
Pulse-on time (Ton)
Pulse-off time (Toff)
Wire feed (Wf)

20
90
106
30
3

30
110
110
35
5

40
130
114
40
-

50
150
118
45
-

The WEDM experiments were performed in order to study the effect of process
parameters on the output response characteristics such as cutting speed and surface
roughness with the help of TAGUCHI method.

4. RESULT AND DISCUSSIONS

Results by Taguchi
The WEDM experiments and using the parametric approach of the Taguchis method
were conducted in this study. In this section, the influence of the various process
parameters on the cutting speed and surface roughness for different experimental
conditions is discussed.

Cutting Speed (CS)

The wire electric discharge machining calculates the cutting speed, and the value is
displayed on the output screen of the CNC interface. For wire electric discharge
machining, cutting speed is a desirable characteristic and it should be as high as
possible to give least machine cycle time leading to increased productivity. In the
present study cutting rate is a measure of job cutting which is digitally displayed on
the screen of the machine and is given quantitatively in mm/min.
Table 3 Response table for cutting rate (Mean data)
Level
1
2
3
4
Delta
Rank

SV
1.7913
1.6009
1.5109
1.3991
0.3922
3

Ip
1.4015
1.6194
1.5266
1.7546
0.3531
4

http://www.iaeme.com/IJMET/index.asp

Ton
0.8268
1.4017
1.8727
2.2009
1.3741
1

311

Toff
1.8111
1.6887
1.5313
1.2711
0.5400
2

WF
1.5340
1.6171

0.0831
5

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi
For example, the average effect on cutting speed (Mean data) for parameters Wf
and Ip at level 1 can be calculated as follows:
Wf = (1.1368+1.6586+2.297+2.223+1.2137+2.1686+0.9046+0.6694)/8= 1.53387
Ip= (1.1368+1.2495+1.2137+2.0061)/4= 1.40075
Table 4 Response table for cutting rate (S/N Data)
Level

SV

Ip

Ton

Toff

Wf

4.762

2.694

-1.892

4.876

2.965

3.035

3.313

2.634

4.036

3.436

3.061

2.824

5.224

2.839

1.945

3.971

6.837

1.052

Delta

2.816

1.276

8.729

3.824

0.471

Rank

For example, the average effect on cutting speed (S/N data) for parameters Ip and
Ton at level 1 can be calculated as follows:
Ip= (1.11368+1.93473+1.68223+6.04705)/4= 2.6944
Ton = (1.11368-3.9582-1.23862-3.48629)/4= -1.8923
Main Effects Plot for Means
Data Means

SV

2.4

IP

TON

2.0

Mean of Means

1.6
1.2
0.8
20

30

40

50

90

110

TOFF

2.4

130

150

106

110

114

118

WF

2.0
1.6
1.2
0.8
30

35

40

45

Figure 2 Effects of response of process parameters on cutting rate (Raw data)

http://www.iaeme.com/IJMET/index.asp

312

editor@iaeme.com

Optimizations of Machining Parameter In Wire EDM For 316l Stainless Steel by Using
Taguchi Method, Anova, and Grey Analysis

Main Effects Plot for SN ratios

Data Means

SV

7.5

IP

TON

5.0

Mean of SN ratios

2.5
0.0
20

30

40

50

90

110

TOFF

7.5

130

150

106

110

114

118

WF

5.0
2.5
0.0
30

35

40

45

Signal-to-noise: Larger is better

Figure 3 Effects of response of process parameters on cutting rate (S/N data)

From figure 2 and 3, it is clear that the cutting rate increases with the increase of
pulse on time, peak current and wire feed, and decreases with increase in pulse off
time and servo voltage. This is because the discharge energy increases with the pulse
on time and peak current which result in faster cutting rate. As the pulse off time
decreases, the number of discharges within a given period becomes more which leads
to a higher cutting rate. With increase in servo voltage the average discharge gap gets
widened resulting into a lower cutting rate. The effect of wire feed on cutting rate is
not very significant.
Selection of optimum process parameters have been made from the response table.
Here response table is used to calculate the effect of each level of process parameter
on performance measure. The response tables 3 and 4 show the average of each
response characteristic (Raw data, S/N data) for each level of each factor. As cutting
rate is the higher the better type quality characteristic, it can be seen from Figure 2
that the first level of wire servo voltage (A1), fourth level of peak current (B4), fourth
level of pulse on time (C4), first level of pulse off time (D1) and second level of wire
feed (E2) provide maximum value of cutting rate. The S/N data analysis (Figure 3)
also suggests the same levels of the variables (A1 B4 C4 D1 E2) as the best levels for
maximum CS in WEDM process.
Larger the better:

S N

HB

10 log (MSD HB )

(1)

where

MSDHB

1 R
2
(1/y j )
R j 1

http://www.iaeme.com/IJMET/index.asp

313

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi

Surface roughness (SR)

One of a good predictor of Wire EDM performance is surface roughness because
nucleation sites can be formed for cracks or corrosion by irregularity in the surface. It
is quantified by the vertical deviations of a real surface from its ideal form. If these deviations are
large, the surface is rough; if small, the surface is smooth. In this work the surface
roughness was measured by Mitutoyo Surftest SRT-8210. In order to see the effect of
process parameters on surface roughness, the average values of surface roughness for
each parameter at levels 1, 2, 3 and 4 for raw data and S/N data are tabulated in table
5 and 6 respectively.
Table 5 Response table for mean surface roughness (Mean data)
Level

SV

Ip

Ton

Toff

WF

3.304

2.187

1.770

2.841

2.701

2.761

2.429

2.353

2.842

2.543

2.248

2.785

2.921

2.514

2.177

3.090

3.446

2.293

1.675

0.548

0.158

Delta

1.127

Rank

0.903
3

Table 6 Response table for surface roughness (S/N data)

Level

SV

Ip

Ton

Toff

WF

-10.168

-6.692

-4.806

-8.810

-8.204

-7.892

-7.266

-7.164

-8.706

-7.554

-6.848

-8.199

-8.979

-7.645

-6.608

-9.359

-10.567

-6.355

Delta

3.560

2.668

5.761

2.455`

0.650

Rank

Method for calculating the response for surface roughness is same as that of the
response for cutting rate. And the same average values for raw data and S/N data are
plotted in figure 4 and 5 respectively. It is clear that the surface roughness increases
with the increase of pulse on time, peak current and servo voltage, and decreases with
increase in pulse off time. There is no significant change in the surface roughness
with the increase of wire feed. The discharge energy increases with the pulse on time
and peak current and larger discharge energy produces a larger crater, causing a larger
surface roughness value on the work piece.

http://www.iaeme.com/IJMET/index.asp

314

editor@iaeme.com

Optimizations of Machining Parameter In Wire EDM For 316l Stainless Steel by Using
Taguchi Method, Anova, and Grey Analysis
Main Effects Plot for Means
Data Means

SV

3.6

IP

TON

3.2
2.8

Mean of Means

2.4
2.0
20

30

40

50

90

110

TOFF

3.6

130

150

106

110

114

118

WF

3.2
2.8
2.4
2.0
30

35

40

45

Figure 4 Effects of response of process parameters on surface roughness (Raw data)

Main Effects Plot for SN ratios
Data Means

SV

-4

IP

TON

-6

Mean of SN ratios

-8
-10
20

30

40

50

90

110

TOFF

-4

130

150

106

110

114

118

WF

-6
-8
-10
30

35

40

45

Signal-to-noise: Smaller is better

Figure 5 Effects of response of process parameters on surface roughness (S/N data)

As the pulse off time decreases, the number of discharges increases which causes
poor surface accuracy. The response tables 5 and 6 show the average of each response
characteristic (raw data, S/N data) for each level of each factor. As cutting rate is the
lower the better type quality characteristic, it can be seen from Figure 4 that the
fourth level of servo voltage (A4),first level of peak current (B1), first level of pulse
on time (C1), fourth level of pulse off time (D4) and second level of wire feed (E2)
provide maximum value of surface roughness. The S/N data analysis Figure 5 also
suggests the same levels of the variables (A4, B1, C1, D4 and E2) as the best levels
for minimum SR in wire electric discharge machining process.
Lower the better:

S N

LB

10 log (MSD LB )

(2)

Where,
MSDLB

1 R 2
(y j )
R j1

http://www.iaeme.com/IJMET/index.asp

315

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi

Result by Anova
In order to predict the optimal values of the machining characteristics, only significant
parameters are considered, and those effect is great on the machining characteristics.
These significant parameters were found using Analysis of Variance (ANOVA) on
S/N data of machining characteristics. Analysis of variance (ANOVA) is a common
statistical technique to determine the percent contribution of each factor for results of
experiments. It calculates parameters known as sum of square (SS), pure SS, variance,
degree of freedom (DOF) and F-ratio. Since the procedure of ANOVA is a very
complicated and employs a considerable of statistical formulae. Results of the
ANOVA are given in the tables 7 and 8 for cutting rate and surface roughness
respectively.
Table 7 Analysis of variance for cutting rate (S/N data)

Analysis of Variance for CS, using Adjusted SS for Tests

Source

DF

Seq SS

Adj SS

Adj MS

SV

0.33001

0.33001

0.011000

4.98

0.172

Ip

0.2664

0.2664

0.08888

4.03

0.205

Ton

4.28091

4.28091

1.42697

64.63

0.015

Toff

0.65170

0.65170

0.21723

9.84

0.094

Wf

0.02766

0.02766

0.02766

1.25

0.379

Error

0.04416

0.04416

0.02208

Total

15

5.60107

S = 0.148585

R-Sq = 99.21%

R-Sq (adj.) = 94.09%

Table 8 Analysis of variance for surface roughness (S/N data)

Source

DF

Seq SS

Adj SS

Adj MS

SV

3.29201

3.29201

1.09734

69.50

0.014

Ip

1.88929

1.88929

0.62976

39.89

0.025

Ton

6.26404

6.26404

2.08801

132.24

0.008

Toff

0.86200

0.86200

0.28733

18.20

0.053

Wf

0.09994

0.09994

0.09994

6.33

0.128

Error

0.03158

0.03158

0.01579

Total

15

12.43885

S = 0.125656

R-Sq = 99.75%

R-Sq (adj) = 98.10%

Optimal value for CS

Form the tables 7, it is clear that three process parameter namely pulse on time (C)
and pulse off time (D) are the most significant process parameters affecting the
cutting rate. Wire feed and peak current shows the least contribution. The optimal
value is predicted using the Eq. (3); the optimum value is calculated as follow,

http://www.iaeme.com/IJMET/index.asp

316

editor@iaeme.com

Optimizations of Machining Parameter In Wire EDM For 316l Stainless Steel by Using
Taguchi Method, Anova, and Grey Analysis
=T

(3)

Here, significant parameters are three in number. So above equation becomes

= T (C
)
= 1.575538+ (2.2009-1.575538)
= 2.2009 mm/min

Prediction of optimal value for SR

Form the tables 8, it is clear that three process parameter namely peak current (B),
pulse on time (C), pulse off time (D) are the most significant process parameters
affecting the surface roughness. Wire feed shows the least contribution. The optimum
value is calculated as the similar way as in case of CR. So the optimum value is,
=T
=T

(3)

(A4 T)

(B1

(C1

(D4

=2.6224 (2.177 2.6224) (2.187 2.6224) (1.770 2.6224) (2.293 2.6224)

= 0.5598 m

Results by Grey relational analysis (GRA)

In GRA, optimization of complicated multiple performance characteristics can be
converted into optimization of a single gray relational grade.

Steps in GRA
GRA consists of three steps:
1. Data Pre-processing (Normalization).
2. Calculating the grey relational coefficients.
3. Calculating the grey relational grade

Step 1:
First step is associated with the normalization of results. When the range of the series
is too large or the optimal value of a quality characteristic is too enormous, it will
causes the influence of some factors to be ignored. The original experimental data
must be normalized to avert such effect. It is the process of transforming the original
sequence to a comparable sequence. Normalization is done in the range of zero and
one, the process is known as grey relational generating. Three types of data
normalization are there in the GRA, lower the better (LB), the higher the better (HB)
and nominal the best (NB).

Lower is better (LB)

(4)

Higher is Better (HB)

(5)

Nominal is best (NB)

(6)

Let the original reference sequence is X0(k).

is normalized value of the kth
element in the ith sequence,
is desired value of the kth quality characteristic,
max
is the largest value of
, and min
is the smallest value of
,
Where i = 1,2,,n; k = 1,2,,p; n (=32) is the number of experiments and p
(=2) is the number of quality characteristics.
http://www.iaeme.com/IJMET/index.asp

317

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi
Step 2:
Second step is to display the relationship between optimal and actual normalized
value. Grey relational coefficient shows such kind of relationship. For this we have to
calculate deviation sequences of the normalized data. The grey relational coefficient
can be expressed as
0,i(k)

(7)

i = 1, ,n; k = 1,,p
where 0,i(k) is the relative difference of kth element between comparative
sequence Xi and the reference sequence X0 (also called GRC),
is the absolute
value of difference between X0(k) and Xi(k). [
= X0(k) - Xi (k) ]
is a distinguishing or identification coefficient, and its value lie between zero and
one. In general it is set to 0.5.
Step 3:
Gray relational grade is the weighting sum of grey relational coefficient. Highest Grey
Relational Grade gives the best multiple machining characteristics. In this research, it
had been taken the average of the grey relational co-efficient as the grey relational
grade. The grey relational grade is determined by Eq. 8.
GRG =

k 0,i(k),

i = 1,2,.,32

(8)

Selection of optimum level

Basically, the larger the grey relational grade, the better is the multiple performance
characteristics. It is clear from table 9 and figure 6 if the process parameter setting on
(A2 B2 C4 D4 E2), then it has the highest grey relational grade. Therefore, A (30V),
B (110 ampere), C (118s), D (45s), and E (5mm/min) is the optimal parameter
combination for multi-machining characteristics. The main effects of each process
parameter on grey relational grade are given in table 9.
Table 9 Response table for mean GRG
Level
1
2
2
4
Delta
Rank

SV
0.5698
0.6333
0.5880
0.5765
0.0634
3

Ip
0.5607
0.6271
0.5844
0.5955
0.0664
2

http://www.iaeme.com/IJMET/index.asp

Ton
0.5509
0.5536
0.6100
0.6530
0.1021
1

318

Toff
0.5969
0.5854
0.5804
0.6050
0.0246
5

Wf
0.5701
0.6137

0.0436
4

editor@iaeme.com

Optimizations of Machining Parameter In Wire EDM For 316l Stainless Steel by Using
Taguchi Method, Anova, and Grey Analysis

Main Effects Plot for Means

Data Means

SV

IP

TON

0.650
0.625

Mean of Means

0.600
0.575
0.550
20

30

40

50

90

110

TOFF

130

150

106

110

114

118

WF

0.650
0.625
0.600
0.575
0.550
30

35

40

45

Figure 6 Shows the graphical representation of values which are tabulated in table 9

5. CONCLUSION
In present work, wire electrical discharge machining (WEDM) for 316L has been
studied. Grey relational analysis (GRA), Anova along with Taguchi method was used
to optimize the Cutting Speed (CS) and surface roughness (SR), simultaneously.
Based on the results and discussions, the following conclusions are made:
Using Taguchi method, CS and SR were optimized individually. The cutting
speed is mostly affected by pulse-on time (Ton) , Pulse off time (Toff) and Servo
Voltage (SV) and surface roughness are mostly affected by the peak current (Ip),
pulse-on time (Ton) , Pulse off time (Toff) and Servo Voltage (SV). Anova has been
applied to find the significant process parameter. Basically, the larger the grey
relational grade, the better is the multiple performance characteristics. The process
parameter setting of (A2 B2 C4 D4 E2) has the highest grey relational grade.
Therefore, A (30V), B (110 ampere), C (118s), D (45s), and E (5 mm/min) is the
optimal parameter combination for multi-machining characteristics.

REFERENCES
[1]
[2]

[3]

[4]

Pandey P. C. and Shan H. S, Modern Machining Processes, Tata McGraw-Hill

Publishing Company, 1980, pp. 79-80.
Li, L.; Dong, C. F.; Xiao, K.; Yao, J. Z.; Li, X. G. Effect of pH on Pitting
Corrosion of Stainless Steel Welds in Alkaline Salt Water. Constr. Build. Mater.
2014, 68, 709715.
Sui, R. J.; Liu, Y.; Wang, W. Q.; Qu, Y. P.; Su, C. G.; Chang, F. Failure Analysis
of Austenitic Stainless Steel Pipes in Amine Liquid Regeneration Unit of a
Desulfurizer. Eng. Failure Anal. 2015, 57, 164170.
Zhiming, L.; Laimin, S.; Shenjin, Z.; Zhidong, T.; Yazhou, J. Effect of High
Energy Shot Peening Pressure on the Stress Corrosion Cracking of the Weld Joint
of 304 Austenitic Stainless Steel. Mater. Sci. Eng, A 2015, 637, 170174.

http://www.iaeme.com/IJMET/index.asp

319

editor@iaeme.com

Manish Saini, Rahul sharma, Abhinav, Gurupreet Singh, Prabhat Mangla and Er.
Amit Sethi
[5]

[6]

[7]

[8]

[9]

[10]

[11]

[12]

[13]

[14]

[15]

Hsu, C.-H.; Huang, K.-H.; Lin, Y.-H. Microstructure and Wear Performance of
Arc-deposited TiN-O Coatings on AISI 304 Stainless Steel. Wear 2013, 306
(12), 97102.
urko i , L.; urko i , . .; alopek, .; en o, M. M.; egota, S.
Enhancement of Corrosion Protection of AISI 304 Stainless Steel by
Nanostructured Sol-Gel TiO2 Films. Corros. Sci. 2013, 77, 176184.
Xing, X. G.; Han, Z. J.; Wang, H. F.; Lu, P. N. Electrochemical Corrosion
Resistance of CeO2-Cr/Ti Coatings on 304 Stainless Steel via Pack Cementation.
J. Rare Earths 2015, 33 (10), 11221128.
T. Hryniewicz, R. Rokicki, and K. Rokosz. Corrosion Characteristics of MedicalGrade AISI Type 316L Stainless Steel Surface after Electro polishing in a
Magnetic Field, January 2016.
Lin Gu, LeiLi, Wansheng Zhao, K. P. Rajurkar (2012), Electrical discharge
machining of Ti6Al4V with a bundled electrode, International Journal of
Machine Tools & Manufacture 53,PP 100106.
O. Dodun, A. M. Gonaclave, L. Slatineanu, G. Nagit (2009), Using wire electric
discharge machining for improved corner cutting accuracy of thin parts, Int. J.
Adv. Manuf. Technol. 41: 858-864.
Susanta Kumar Gauri, Shankar Chakraborty (2009), Multi-response optimization
of WEDM process using principal component analysis, Int. J. Adv. Manuf.
Technol, 41, pp. 741-748.
U. D. Gulhane, A. B. Dixit, P. V. Bane, G. S. Salvi. Optimization of Process
Parameters for 316l Stainless Steel Using Taguchi Method and Anova.
International Journal of Mechanical Engineering and Technology, 3(2), 2012,
pp. 6772.
Vishal Francis, Ravi.S.Singh, Nikita Singh, Ali.R.Rizvi and Santosh Kumar.
Application of Taguchi Method and Anova in Optimization of Cutting
Parameters for Material Removal Rate and Surface Roughness in Turning
Operation. International Journal of Mechanical Engineering and Technology,
4(3), 2013, pp. 4753.
Ramkrishna Parihar and Sanjay Jathar Application of Taguchi Method to
Optimize Tensile Shear Strength between Stainless Steel Aisi304 and Mild Steel.
International Journal of Mechanical Engineering and Technology, 6(10), 2015,
pp. 194201.
Amit Sethi Determine Optimum process parameters in Wire Electric Discharge
Machining (WEDM) on Titanium (Ti6Al7Nb) Alloy by using Grey Relational
Analysis, 2013.

http://www.iaeme.com/IJMET/index.asp

320

editor@iaeme.com