Wire electrical discharge machining is one of the advanced non-traditional machining processes used only for machining of conductive materials. Wire electrical discharge machining works on the principle of spark erosion. The spark generated between the work piece and the wire electrode which melts the work piece and the chips are carried away by the pressurized di-electric fluid. The main objective of the present work was to investigate the effect of process parameters on surface roughness and material removal rate of KOYAR material. The lower coefficient of thermal expansion of the kovar material qualifies the metal to be best used in vacuum tubes, light bulbs, microwave tubes and cathode ray tubes application, especially for glass to metal and ceramic to metal joints. The L-9 orthogonal array designed by Taguchi was used to reduce the number of experiments by varying four main parameters of wire electrical discharge machining to optimise the surface roughness and material removal rate. In this study,parameters varied are pulse on time, pulse off time, open circuit current and material thickness. Minitab, a statistical software was used to analyse the variances between different factors influencing surface roughness and material removal rate. The individual regression equations for the response variables were formed and confirming experiments were performed. The variation between the experimental and the theoretical results were in good agreement. The contribution of each factor on response variable was estimated. The results helped in achieving Ra value of less than 1.1 micrometer which is a requirement in vacuum electronic device industry with an enhanced material removal rate.

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