Optimization of Machining Parameters of EN-27 Material Using Wire Electric Discharge Machining (WEDM)

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Year : 2026 | Volume : 16 | 01 | Page :
    By

    Ritesh Fegade,

  • Veerabhadrappa Sulepeth,

  • Suraj Londhe,

  • Balkrushna Bongale,

  • Avinash Ushir,

  • Sakshi Shelar,

  1. Associate Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Pune, Maharashtra, India
  2. Assistant Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Pune, Maharashtra, India
  3. Student, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Pune, Maharashtra, India
  4. Student, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Pune, Maharashtra, India
  5. Student, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Pune, Maharashtra, India
  6. Student, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Pune, Maharashtra, India

Abstract

The optimization of Wire Electrical Discharge Machining (WEDM) parameters for EN-27 alloy steel, a high-strength material widely utilized in mechanical and structural applications, is the subject of this study’s methodical analysis. Due to its hardness and poor machinability by conventional methods, WEDM is preferred for achieving precise dimensional accuracy and surface integrity. The primary objective of this work is to enhance machining performance by identifying optimal process parameters influencing Material Removal Rate (MRR) and Surface Roughness (SR).

The experimental design was developed using the Taguchi method to minimize the number of experimental runs while ensuring statistical reliability. Four key machining parameters pulse on time, pulse-off time, voltage gap, and wire feed were selected as control factors. An L16 orthogonal array was employed to conduct the experiments, and the results were analyzed using Analysis of Variance (ANOVA) to determine the significance of each parameter on the selected responses.

The experimental results indicate that pulse on time is the most influential parameter affecting MRR, as increased discharge duration leads to higher spark energy and enhanced material erosion. Voltage gap was also found to significantly influence both MRR and SR by regulating discharge stability and energy distribution. Pulse off time and wire feed exhibited relatively lower individual contributions; however, they play an important role in maintaining machining stability and surface quality. ANOVA results confirmed the statistical dominance of pulse-on time and voltage gap. The optimized parameter settings resulted in improved machining efficiency and surface finish, demonstrating the suitability of WEDM for machining EN-27 alloy steel in advanced manufacturing applications.

Keywords: WEDM, EN-27 Steel, Taguchi Method, ANOVA, MRR, Surface Roughness.

How to cite this article:
Ritesh Fegade, Veerabhadrappa Sulepeth, Suraj Londhe, Balkrushna Bongale, Avinash Ushir, Sakshi Shelar. Optimization of Machining Parameters of EN-27 Material Using Wire Electric Discharge Machining (WEDM). Journal of Production Research & Management. 2026; 16(01):-.
How to cite this URL:
Ritesh Fegade, Veerabhadrappa Sulepeth, Suraj Londhe, Balkrushna Bongale, Avinash Ushir, Sakshi Shelar. Optimization of Machining Parameters of EN-27 Material Using Wire Electric Discharge Machining (WEDM). Journal of Production Research & Management. 2026; 16(01):-. Available from: https://journals.stmjournals.com/joprm/article=2026/view=238618


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Ahead of Print Subscription Original Research
Volume 16
01
Received 28/01/2026
Accepted 06/02/2026
Published 24/02/2026
Publication Time 27 Days
49

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