Minimizing Wire Breakage in Wire Electric Discharge Machining Using Multi-Objective Artificial Bee Colony Algorithm

Abstract

Wire breakage in wire electric discharge machining (WEDM) is a serious issue causing in-between stoppage resulting into time loss, wastage of wire, and excessive energy utilization. Hence to achieve higher machining productivity of WEDM process, it is necessary to prevent wire breakage and also to improve material removal rates. Multi-objective optimization for maximizing material removal rate (MRR) and minimizing wire breakage in WEDM process is therefore presented in this work. A novel approach of maximizing tension sustained by the used wire for minimizing wire breakage is presented through an industrial case study. The effect of independent variables such as pulse on time, pulse off time, peak voltage, dielectric fluid pressure, wire feed rate, machine speed, and cutting speed override on dependent variables, wire breakage frequency and material removal rate is studied to formulate the optimization model based on response surface modeling. Multi-objective version of artificial bee colony algorithm is used for optimization. The set of Pareto optimal solutions obtained by this proposed approach provides a ready reference to select most appropriate parameter setting on the machine.