Parametric Analysis and Multi-objective Optimization for Machining Complex Features on D2 and DC53 Steels for Tooling Applications

Hardened AISI D2 and DC53 tool steel has widespread applications in the tool and die-making industry. Conventional machining of D series tool steels is challenging due to the presence of hard and abrasive metallic carbides, which limit the cutting tool’s life. Therefore, wire electric discharge machining (WEDM) is a precision material removal process widely used for incorporating intricate details on hardened steels through material removal. Thus, this study evaluates the effect of machining parameters like peak current (I_P), servo voltage (V), pulse (P), and material type (MT) in terms of surface roughness (Ra) on complex profiles such as flat and curved. An analysis of variance has also been carried out to investigate the significant input parameters for the WEDM. To find the optimal parametric settings, multi-response optimization with composite desirability (d_G) has been performed. Among the two types of materials, D2 steel has performed exceptionally well in terms of Ra for both flat and curved surfaces. The confirmatory experimental results revealed improvement in flat and curved profile roughness by 66.03% and 60.09%, respectively.