Analysis of WEDM Process Parameters on Surface Roughness and Kerf using Taguchi Method

Asfana Banu,Mohammad Yeakub Ali,Erry Y. T. Adesta,Mazilah Abu Bakar

doi:10.26776/ijemm.02.04.2017.04

Abstract

In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap.

Highlights

Wire electrical discharge machining (WEDM) is a specialized thermal machining process used to machine complex shape components with high accuracy using a thin single-strand metal wire (0.1 or 0.25mm diameter) as an electrode
All of the process parameters that have been used for the investigation were found to have influence on the surface roughness and kerf
The following conclusions are drawn from the experimental study: 1. From S/N ratio, it can be inferred that wire speed, wire tension, and voltage gap should be at the highest level, which is level 4 while voltage open and off time should be at level 3 and 4 respectively to obtain low surface roughness

Summary

Introduction

Wire electrical discharge machining (WEDM) is a specialized thermal machining process used to machine complex shape components with high accuracy using a thin single-strand metal wire (0.1 or 0.25mm diameter) as an electrode. It is a technique used in industry for high-precision machining of all types of conductive materials such as metals, metallic alloys, graphite [1,2,3]. It is known as an electro-erosion machining process. Without WEDM, the fabrication of precision workpiece requires many hours of manual grinding and polishing [5]

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Conclusion