The only the least possible number of trials. Yet

The technology of Wire Electro Discharge Machining (WEDM) has
undergone significant improvements to meet the requirements in different
manufacturing fields 1 2. In WEDM, a wire is used as an electrode and
deionized water as a dielectric. The electrodes (wire and the work piece) are
connected to a pulsed DC supply. The sparking between both the electrodes leads
to the generation of heat which results in the melting of the work piece and
the wire. A nozzle is employed to inject the dielectric into the machining
area. The dielectric functions both as a coolant and also flushes away the
eroded material. With the help of a computer based positioning system it is
possible to maintain a constant gap between the wire and the work piece. Wires
of diameters 0.05-0.30mm are used here which helps us cut difficult contours in
hard to machine surfaces. Hence WEDM is especially useful in fields where a
high degree of accuracy and surface finish is a pre requisite. Hence WEDM finds
a wide application in industries such as Aerospace, Medical, Semiconductor, and
Tool and Die making, Micro Tooling, etc. The optimization of the process
parameters of a manufacturing process is necessary to achieve a high rate of
production. In WEDM operation, the material removal rate (MRR) determines the
economics of machining and also the rate of production. Cylindricity is a
measure of the deviation of a machined surface from that of a perfect cylinder.
The surface roughness (Ra) is a measure of the quality of the machining
process 4.

An experimental investigation is conducted with the aim of
optimizing the WEDM process 5 in order to improve the above discussed quality
characteristics namely MRR, Cylindricity and Surface Roughness. Several
researches have been carried out by researchers showcasing the techniques
involved in the selection of the optimal parametric values for MRR3 and
Surface finish3.Taguchi method has been widely used in the selection of the
process parameters. Taguchi method makes use of Orthogonal Arrays (OAs) 6 for
designing the experiments. The predominant advantage of this technique lies in
its simplicity and adaptability. They provide the required information making
use of only the least possible number of trials. Yet they yield reproducible
results with good precision. 

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