Parametric Optimization of Machining Parameters of
AISI D3 Tool Steel Using Wire Cut Electric
Discharge Machining – A Taguchi Based Approach
Jignesh R.Vaghela, Janak B.Valaki, Jaysukh H.Pandit.
Mechanical Engineering Department,
G.E.C. Bhavnagar.
Bhavnagar, Gujarat, India.
jigneshvaghela030@gmail.com.
Abstract—This work reports about the Taguchi approach for
parametric optimization for WEDM parameters like peak
current, pulse on time and pulse off time for material removal
rate, kerf width and surface roughness. Experiments were
designed and planned using Taguchi L-9 orthogonal array.
Signal-to-Noise ratios have been calculated from experimental
observations. The significant parameters that critically influence
the machining characteristics were examined by ANOVA. A
mathematical model is developed for predicting the response
quality using regression analysis. Further experiments were
conducted with optimized parameters to authenticate the
usefulness of proposed investigation. The confirmation
experiment result shows that the model suggested by Taguchi’s
method is suitable for improving selected responses.
Index Terms—WEDM, DOE, ANOVA, Taguchi Method,
MRR, Surface Roughness, Kerf width.
I. INTRODUCTION
Nontraditional manufacturing processes like Wire cut
Electric Discharge Machining (WEDM) is used for precision
manufacturing of various industrial parts with closest
dimensional accuracy [1]. In WEDM process there is a
continuous moving wire between uptake pulley and down take
pulley, the work is clamped on setup. When the conductive
wire comes to the nearest point to work piece then the high
voltage produces an ionization channel in between, in the
second stage there will be a discharge of arc. This arc melts
and evaporates the work metal. This sparking action will took
place over the periphery of wire electrode, and generates a
precise gap (kerf width) between two edges. Then the debris
generated by sparks will flushed away by a fluid known as die
electric fluid, which carries the eroded particles. Throughout of
process there won’t be any surface contact between wire and
work piece. So, without any upper limit of hardness any kind
of conductive material can be machined. With the advancement
of NC technology, multi axis machining and submerged
machining, WEDM is one of the best alternative sometimes the
only alternative to implement.
In WEDM one of the most investigated research areas are
modelling and optimization as a result of which we have less
production cost with improved job quality. In short, due to
highly stochastic nature of process, the complicated
interactions between process parameters, current analytical
models and analyses cannot provide accurate process
prediction for better quality control and higher throughput [2].
Hence, an efficient method is needed to determine the optimal
machining parameters.
In the case of WEDM, the most significant performance
indicators are metal removal rate (MRR), Kerf width and
surface finish. In WEDM, because it is a complex a stochastic
process, it is very difficult to determine the optimal machining
parameters for the best machining performance. Moreover, the
performance measures, namely MRR, Kf and Ra, are
conflicting in nature as it is desirable to have higher MRR with
lower value of kerf and surface roughness.
Wuyi Ming [3] conducted the experiments designed based
on Taguchi method for processing off tungsten steel YG15 and
developed a linear model of MRR and 3D surface quality (Sq
and Sz). For SKH 57 high speed steel material, the effects of
machining parameters under EDM were investigated by Yang
Lin [4]. L18 orthogonal array by Taguchi method was
proposed for experiments. Cryogenic treated AISI D2 tool steel
was chosen by M.M. Dhobe [5] to optimize surface roughness
after machining under WEDM. L9 orthogonal array was
applied as a technique of DOE to plan experiment sequence
and by signal to noise ratio, optimal parameters were contrived.
Kanlayasiri and Boonmung [6] have validated the model of
surface roughness of DC 53 die steel, for which ANOVA
shows that pulse-on time and pulse-peak current are significant
variables. Kiyak and Akir [7] have concluded that lower
current and higher Pulse-off time on EDM produces a better
surface finish on machining the tool steel (AISI P20), which is
widely used in the production of mold and die. Hesam Shahali
[8] have minimized surface roughness and white layer
thickness of DIN 1.4542 stainless steel by signal to noise ratio
and micro GA optimization techniques under WEDM. The
discharge power and number of finish passes have
consecutively significant influence on the surface roughness
and thickness of the white layer.
A factorial design model was developed by Dan Scott to
measure material removal rate and surface finish as a function
of six different control parameters. Analysis of variance shows
that discharge current, pulse duration and pulse frequency were  Chemical Composition of AISI D3 Material:
significant control factors for both MRR and SF while wire The compositional range for Cold-work tool steel D-3 is
speed, wire tension and dielectric flow rate were relatively provided in the table 1 given below.
insignificant.[9]
Shyam Lal and Sudhir kumar [10] have investigated the TABLE I. MATERIAL SPECIFICATION: COLD-WORK TOOL STEEL D-3.
order of significance of factors was pulse on time, pulse Element C Si Mn P S Cr Ti Fe
current, pulse off time and the wire drum speed on kerf width Value 2.01 0.67 0.35 0.023 0.025 11.41 0.3 B*
and surface roughness by ANOVA. The Taguchi-based grey *B= Balance.
relational analysis, a multi-response optimization technique, Different setting of three controlling factors such as peak
was used to find the optimal WEDM process parameter setting current, pulse on time and pulse off time were selected based
for Al7075/Al2O3/SiC hybrid composite, further converging on past literature. As literature review reveals that significance
the observation to MRR [11], pulse on time is the highest of wire tension and wire feed rate is least on chosen
contributing factor nearer to 50% and wire drum speed has the performance parameters more over considering machine
least significance. They found the optimum value of surface limitations values of wire tension and wire feed rate were kept
roughness nearer to 2.08 mm and the surface topography constant.
analysis [12] depicted that SR is high at high level of process
parameters setting. Liquid-like formation was observed in all A block of 150×50mm having thickness of 5mm was cut as
the SEM pictures. work piece and the angle of cut was vertical. After considering
machining conditions, out of several available controllable
Ergun Ekici [13] proposed a Taguchi method based input parameters on the wire EDM machine, following
optimization of MRR and SR for Al/B4C composites. The L18 parameters were selected with maximum feasible range.
experiments shows that the most effective WEDM parameters
to be pulse-on time (30.22%) for surface roughness and wire TABLE II. VARIABLE PARAMETER AND THEIR SELECTED LEVEL FOR
speed (83.20%) for material removal rate while wire tension EXPERIMENT
was ineffective. K.P.Somashekhar [14] applied Taguchi and
Symbol Control Factors Symbol Unit Level 1 Level 2 Level 3
Gray Rational Analysis (GRA) for finding optimum machining
condition. Over cut and MRR increases with capacitance and Peak
eventually surface will become rough. A Ip Amp. 3 4 5
Current
K.H. Ho and S.T. Newman [15] reviewed the research Pulse on
work from the inception to the development of die-sinking B Ton µs 16 32 48
Time
EDM within the past decade. However, several means of Pulse off
improving the machining performance commonly measured in C Toff µs 4 8 12
Time
terms of MRR, TWR and SR have been made with an
overwhelming research interest being paid to the metallurgical TABLE III. CONSTANT PARAMETERS (MACHINING CONDITION).
properties of EDMed part. Dielectric De-ionized water
M.S. Hewidy [16] investigated that the development of Dielectric Conductivity 38 mohs
mathematical models for correlating the inter-relationships of Wire Tension 1.2 kg
Work piece material Cold-work tool steel D-3
various WEDM machining parameters of Inconel 601 material
Wire Type Molybdenum 0.18 mm diameter
such as: peak current, duty factor, wire tension and water Flushing pressure 1.2 MPa
pressure on the metal removal rate, wear ratio and surface
roughness. S. Sarkar [17] investigated the features of trim
cutting operation of wire electrical discharge machining of ɤ- III. EXPERIMENTAL DESIGN
titanium aluminide. A second-order mathematical model, in The experimental studies were performed on CONCORD
terms of machining parameters, was developed for surface CNC wire EDM machine, model no DK-7720, manufactured
roughness, dimensional shift and cutting speed using response by Jian Nan Saitec NC Co Ltd. The electrode material used is
surface methodology (RSM). 0.18 mm diameter molybdenum wire and di-electric fluid used
II. MATERIALS AND METHODS is demineralized water.
In the investigation cold worked tool steel AISI D-3 was
the target work material with a molybdenum electrode of
diameter of 0.18mm. Table 1 shows the material related
properties.
AISI D3 steel is oil-quenched and contains 1.5 to 2.35% of
carbon and 12% of chromium. It contains additional carbon,
which increases wear resistance.
 (d)
Figure 1. (a) Experimental equipment of Wire-cut Electric Discharge
Machine, (b) Zoom in view of cutting zone, (c) Cutting process, (d) The
workpiece samples produced.

(a)
 Measurement of Response Parameters:
This study investigates the machining characteristics such
as material removal rate (MRR), kerf width (Kf) and Surface
Roughness (Ra). This is the most common key indicators used
by many manufacturers. Theoretically, material removal rate is
expressed as the ratio of the multiplications of kerf width with
work piece thickness and length of cutting to the cutting time.
MRR (mm3/min) = Kf × t × l … (1)
Where, Kf = Kerf width in mm, t = Thickness of Work
piece in mm and l = Cutting length in mm per unit time.
Kerf width is defined as the measure of amount of material
wasted during machining process; kerf determines the
dimensional accuracy of the finishing part. Here kerf width is
measured by Almicro toolmakers microscope, model no. KW-
900 (L.C. 0.01 to 0.005 mm with goniometer. Fixed
magnification 30x.) Surface Roughness measure as the
arithmetic average, Ra (µm). The Ra value, also known as
center line average (CLA) is obtained by averaging the height
(b) of the surface above and below the centre line. The Surface
roughness measured using a surface roughness tester from
Mitutoyo, Model: SJ 210.
IV. EXPERIMENTAL RESULTS AND MODELLING RESPONSE
VARIABLES
Experiments were performed according to DOE based L9
OA design, and results of desired responses are illustrated in
table 4. In this work statistical models have been developed to
predict MRR, Kf and Ra in the Wire EDM process. The
influence of input WEDM parameter Ip, Ton and Toff on the
selected response variable have been assessed. Due to non-
linear behavior of process a multiple linear regression models
were postulated in obtaining the relationship between process
parameters and response variables. [18]
To perform experiments in systematic manner, statistical
software Minitab17 is used for DOE and ANOVA analysis.
(c)
 TABLE IV. FULL FACTORIAL L-9 ORTHOGONAL ARRAY OBSERVATION Ton 1 0.000134 0.000134 0.000134 12.31 0.072
TABLE SHOWING EXPERIMENTAL RESULTS. Toff 1 0.000016 0.000016 0.000016 1.49 0.346
Input Ip*Ton 1 0.000060 0.000060 0.000060 5.46 0.145
Output Parameters Ip*Toff 1 0.000007 0.000007 0.000007 0.63 0.510
Parameters
Ex. Ton*Toff 1 0.000007 0.000007 0.000007 0.63 0.510
S/N Kerf S/N MRR S/N
No. Ip Ton Toff Ra
ratio Width ratio (mm3/ ratio Error 2 0.000022 0.000022 0.000011
(A) (µs) (µs) (µm)
Ra (mm) Kf min) MRR Total 8 0.001058 0.001058
1 3 16 4 2.229 -6.96220 0.230 12.7654 4.100 12.7654 S=0.0033022, R-sq=97.94%, R-sq(adj)= 91.75%

2 3 32 8 2.348 -7.41396 0.235 12.5786 2.394 12.5786

The ANOVA for the complete model of different responses
3 3 48 12 2.347 -7.41026 0.247 12.1461 1.331 12.1461 have been illustrated above. Table 5, 6 and 7 shows that the
4 4 16 8 1.857 -5.37624 0.233 12.6529 1.594 12.6529
values of “F-value” and “Prob. > F” (α=0.05, or 95%
confidence) for each term on the performances of MRR, Kf
5 4 32 12 2.063 -6.28998 0.238 12.4685 2.360 12.4685 and Ra, respectively. Most of the values of P are less than 0.05,
6 4 48 4 2.479 -7.88553 0.260 11.7005 4.132 11.7005 which means that the model is effective. [19], [20]
It is clear from the p values of Analysis of variance for
7 5 16 12 1.925 -5.68861 0.236 12.5418 2.206 12.5418
MRR, Kf and Ra that the predicted model is accurate, and from
8 5 32 4 2.589 -8.26264 0.255 11.8692 6.029 11.8692 the percentage contribution of residual error is quite negligible
than other parameters, Which strengthens the analysis because
9 5 48 8 2.576 -8.21892 0.252 11.9720 3.272 11.9720
it is on minimum side.
The ANOVA was used to check the adequacy of the
developed models. Analysis provides the variance of
controllable and noise factors. By understanding the source and V. TAGUCHI BASED OPTIMIZATION
magnitude of variance, robust operating condition can be The variations caused in the surface roughness during the
predicted. repetitive trials are expressed by calculating the S/N ratio
Table 5 shows the ANOVA for MRR. The P-value, Fvalue value. Of all the available options, ‘‘smaller the better’’ is
and R2 are computed for the model at 95% confidence level. A considered for Ra and Kf and “higher the better” for MRR.
similar analysis is carried out for Ra and Kf are given in Table Following equation gives the S/N ratio is denoted by ‘‘η’’ and
6 and 7 respectively. expressed in dB.
S/N ratio for surface roughness and kerf width;
TABLE V. ANALYSIS OF VARIANCE FOR MEAN VALUES OF MATERIAL
REMOVAL RATE (MRR) η= -10log1/n
Source DOF Seq SS Adj SS Adj MS F P S/N ratio for Material Removal Rate;
η= -10log1/n
Ip 1 0.7714 0.7714 0.77135 0.49 0.557
The measured MRR, Ra, Kf and the calculated S/N ratio
Ton 1 0.0713 0.0713 0.07131 0.05 0.851
Toff 1 0.4493 0.4493 0.44927 0.28 0.647 for the experiments designed and conducted on AISI D3 tool
Ip*Ton 1 0.2466 0.2466 0.24658 0.16 0.731 steel are shown in table given below.
Ip*Toff 1 0.0475 0.0475 0.04752 0.03 0.878 The mean S/N ratio values of all responses for every level
Ton*Toff 1 0.4593 0.4593 0.45930 0.29 0.643 are tabulated in Table 8, 9 and 10 are represented graphically in
Error 2 3.1532 3.1532 1.57661
Fig. 2.
Total 8 17.5716 17.5716
S=1.25563, R-sq=82.06%, R-sq(adj)=28.22%
TABLE VIII. RESPONSE TABLE FOR S/N RATIO FOR MATERIAL
REMOVAL RATE (MRR) - LARGER IS BETTER.
TABLE VI. ANALYSIS OF VARIANCE FOR MEAN VALUES OF SURFACE Sr. No. Level Ip Ton Toff
ROUGHNESS (Ra)
1 1 7.441 7.726 13.395*
Source DOF Seq SS Adj SS Adj MS F P
2 2 7.944 10.215* 7.310
3 3 10.924* 8.368 5.605
Ip 1 0.000004 0.000004 0.000004 2.61 0.993
Ton 1 0.000154 0.000154 0.000154 0.00 0.957
Toff 1 0.019390 0.019390 0.019390 0.00 0.564 TABLE IX. RESPONSE TABLE FOR S/N RATIO FOR SURFACE
Ip*Ton 1 0.000001 0.000001 0.000001 0.47 0.997 ROUGHNESS (Ra) - SMALLER IS BETTER
Ip*Toff 1 0.005417 0.005417 0.005417 0.00 0.752 Sr. No. Level Ip Ton Toff
Ton*Toff 1 0.032038 0.032038 0.032038 0.13 0.471 1 1 -7.262 -6.009 * -7.703
Error 2 0.082405 0.082405 0.041203 0.78 2 2 -6.517* -7.322 -7.003
Total 8 0.728580 0.728580 3 3 -7.390 -7.838 -6.463*
S=0.202985, R-sq=88.69%, R-sq(adj)=54.76%
TABLE X. RESPONSE TABLE FOR S/N RATIO FOR KERF WIDTH (Kf) -
TABLE VII. ANALYSIS OF VARIANCE FOR MEAN VALUES OF KERF SMALLER IS BETTER
WIDTH (Kf) Sr. No. Level Ip Ton Toff
Source DOF Seq SS Adj SS Adj MS F P 1 1 12.50 12.65 12.11*
2 2 12.27 12.31 12.40
Ip 1 0.000094 0.000094 0.000094 8.60 0.099 3 3 12.13* 11.94* 12.39
 In general, the S/N ratio is selected on the basis of their
characteristics; and a higher value of S/N ratio represents
better performance. Therefore, of all the three levels, the
optimal level parameters are selected corresponding to the
higher values of S/N ratio. The optimal parameter combination
obtained is A3B2C1 (Table 8), A2B1C3 (Table 9) and
A3B3C1 (Table 10) for getting optimum material removal
rate, surface roughness and kerf width respectively. With this
optimal parametric combination, separate experiments were
conducted.
(a)
(b)
(c)
Figure 2. Effects of Process Parameters on Material Removal Rate.
 Regression Model
Multiple regression (MLR) models by regression analysis,
are suitable to formulate complicated problems with many
dependent and independent variables within a certain range. It
gives the relationship between independent variables and
out to estimate the surface roughness as a response. The
mathematical models suggested are as given in Eq. (2), (3) and
(4).
Material Removal Rate (MRR):
MRR = 2.56+1.43*Ip+0.052*Ton-0.92*Toff-0.0287*Ip*Ton+
0.050*Ip*Toff+0.0098*Ton*Toff… (2)
Kerf Width (Kf):
Kf = 0.1799+0.01581*Ip+0.002235*Ton-0.00554*Toff-
0.000446*Ip*Ton+0.000607*Ip*Toff+0.000038*Ton*Toff
… (3)
Surface Roughness (Ra):
Ra = 2.67+0.003*Ip-0.0024*Ton-0.191*Toff+0.0001*Ip*Ton
+0.017*Ip*Toff+0.00259*Ton*Toff… (4)
Where, the values of the variables have been specified as
per their original units.
Fig. 3, shows the comparison between experimental and
predicted response values as per the suggested mathematical
model. There is close agreement between experimental values
and the values calculated using the developed model. Thus, the
suggested equation is much useful for predicting the MRR, Kf
and Ra of AISI D3 tool steel in WEDM.
(a)
(b)
(c)
Figure 3. Comparison between experimental and predicted values of
MRR, Kf and Ra.
 VI. CONFIRMATION EXPERIMENT
The results obtained by Taguchi’s design of experiments
analysis are validated by conducting the confirmation
experiments. The experiments were conducted as per the
optimized parameter combinations. The last stage in the
process is the confirmation. This is done by comparing
predicted values and the experimental result. Table 10 gives the
comparison between predicted values of roughness and S/N
ratio and trial results. The S/N ratio has been improved from
the initial machining parameter settings to that of optimum
machining parameter combinations A3B2C1 (MRR), A2B1C3
(Ra) and A3B3C1 (Kf). MRR increases as well as Ra and Kf
are decreases. This shows that the approach used in this paper
is justified and provides corrective indication of improvement
in output parameters considerably.
The values of responses given by mathematical model and
experiments are given in the below table for comparison, there
exists a close correction between experimented and predicted
values. Hence, it confirms the validity in applying the Taguchi
method for selecting and optimizing machining parameters.
Then the obtained optimal solution of this approach was
compared with validation tests. Minitab 17 used to analyze the
variance of experimental data (ANOVA).
The regression model has successfully predicted the result
that matches with the experimental values. Experimental
results and present analysis confirm that the parameter levels
obtained are useful for predicting the optimum combinations of
factors and corresponding responses for cold worked tool steel
D-3. Therefore, the cold worked tool steel D-3 can be widely
accepted worldwide as a standard material in manufacturing of
forming tools to produce die castings, press tools in sheet metal
industries, forging dies, etc.
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