Mapping of WEDM Output from Designed Experiments to Binary Symmetric Channel

Wire-electro discharge machining (WEDM) has become an important non-traditional machining process, widely used in the aerospace, nuclear, and automotive industries. The electrode that is used for WEDM is a tiny flexible brass wire; therefore in the WEDM machining process, the wire behaviors and the influence of parametric conditions on the workpiece need to be well estimated. The investigations and simulations of Wire-EDM are useful for different machining conditions in practical scenarios. The channel coding methodology-based approach is utilized to simulate the machining parameters for a better material removal rate (MRR) of the workpiece of E0300 die steel. In the present work, a binary symmetric channel (BSC) is used for the information that can be transmitted through the channels with encoding and decoding techniques. The various WED machining parameters selected are TON, TOFF, IP, VP, WF, WT, and SV. Mathematical models are also developed to correlate the interrelationship of important factors which invariably helps for prediction of MRR during machining. The objective of this development is to estimate the MRR based on the channel coding approach and verification of the results with the experimental machining parametric settings. The paper also highlights the various test results that confirm the ability of the proposed system to analyze the effect of the various process parameters of WEDM during the machining of E0300 alloy steel. The investigation also describes a simulating procedure, developed algorithms, and a few analyzed results of Wire-EDM. The simulated values of the machining parameters obtained through the approach can be recorded and organized for a better and more effective database system.