Effect of wire materials on performance during WEDM of SS304

Abstract

Traditional machining methods are being replaced by unconventional machining processes as the need for high surface quality, and machining of complicated form geometries grows, and Wire electric discharge machining (WEDM) is one of the unconventional machining processes. Stainless Steel 304 (SS304) is widely utilized in the aerospace, medical, electronic, and semiconductor sectors, as well as tool and die manufacturing. However, because of limited heat conductivity and a high built-up edge (BUE) affinity, industries encounter substantial complexities during traditional machining of SS304, such as excessive tool wear and high surface roughness values.Current study analyses the influence of current (I), pulse on time (Ton), pulse of time (Toff), and voltage (V) using two different electrode wire materials (Brass and Zinc coated brass), considering the numerous uses and obstacles in conventional machining of SS304 alloy. The material removal rate (MRR) and kerf of the machined surfaces were determined after each trial to determine the SS304’s machinability.Employing Taguchi's L18 orthogonal array, WEDM experiments were carried out in a WEDM machine using I (1, 3, 5 Amps), Ton (105, 110, 115 µs), Toff (25, 35, 45 µs), and V (20, 30, 40 V).From the experimental results, it was found that the coated brass wire had a higher material removal rate than the uncoated brass wire in the experimental trial. Low kerf was detected in an uncoated brass wire of the machined surfaces at the same time. Finally, grey relational analysis (GRA) was used to reduce the kerf and maximize the MRR simultaneously.