Now a days high value-added to manufacturing section is essential under the situations of the high precision requirements of industrial products or the high labor cost. Wire-cut EDM is one of the modern cutting technologies is high precision cutting for thickness workpieces. This method is capable of quickly and easily cutting complex shapes while achieving very high tolerances. The present study is on effect of work-piece thickness on responses w.r.t process parameters. The operation was performed on the aluminum alloy AL6063-T6 using L8- Orthogonal array of Taguchi method. The measuring responses are surface roughness (Ra) and Material Removal Rate (MRR) with input parameters as workpiece thickness (w/p-t), pulse on time (Ton), pulse off time (Toff), wire tension (WT), wire feed (WF) and dielectric flushing pressure (WP). Result data was analyzed using Minitab software with the help of ANOVA, contour plots, surface plots and multi response optimization. Ra is decreasing with increasing of work-piece thickness and Ra is increasing with decreasing of work-piece thickness w.r.t process parameters. MRR is increasing with increasing of work-piece thickness and MRR is decreasing with decreasing of work-piece thickness w.r.t process parameters.

Keywords : Wire-cut EDM, AL6063-T6, Taguchi, ANOVA, Ra, MRR, w/p-t, Ton, Toff, WT, WF and WP