Abstract
The purpose of this research is to obtain the optimum cutting parameters to achieve the dimensional accuracy of Nimonic alloy miniature gear manufactured using Wire EDM. The cutting parameters investigated in this study are current, pulse on time (PON), pulse off time (POFF), wire tension (WT) and dielectric fluids. Ethylene glycol, nanopowder of alumina and oxygen are mixed to demineralized water to prepare novel dielectric fluids. Deviation in inner diameter, deviation in outer diameter, deviation in land and deviation in tooth width are considered to check the dimensional accuracy. Taguchi L-16 is employed for experimental design and multiple response optimization is performed using Entropy TOPSIS and Pareto ANOVA. Results indicate that pulse on time is the most notable parameter for good dimensional accuracy followed by dielectric fluid, current, pulse off time and wire tension. Ethylene glycol mixed demineralized water is preferred for low dimensional deviation. The optimum WEDM parameters are pulse on time at 20 mu s, Ethylene glycol mixed demineralized water dielectric fluid, current at 3 A, pulse off time at 4 mu s, and wire tension at 18 N.