Analysis of machining parameters for wire cut electrical discharge machining of pure titanium using response surface methodology

Abstract

Machining of pure sintered titanium by conventional technique is difficult because of its very high specific strength, abrasion and corrosion resistances and finds immense applications in bio-implants and aerospace components. Wire Cut Electrical Discharge Machining (WEDM) has evolved as one of the most important non-traditional machining processes because of its uniqueness towards producing components which are difficult to machine like titanium, tungsten carbide, Inconel etc and also give a platform for producing intricate complex shape which might be impossible to machine by conventional machining methods. In the present work, Wire Cut Electrical Discharge Machining on pure sintered titanium is studied. The different input parameters of Wire Cut Electrical Discharge machining like, pulse on time, pulse off time, wire tension and wire feed have been varied to investigate the output response like Kerf Width and Over Cut. A response surface methodology (4 factors 3 level) design of experiment (DOE) has been applied in this context to examine the machining ability of pure sintered titanium and results are found to be satisfactory and verified by confirmatory test. The machining parameters like pulse on time, pulse off time, wire tension and wire feed shows immense effect on the output responses and present study provide an optimal conditions of these input parameters to get the best output responses through response surface methodology.