Experimental investigation of 3D taper profile machining of SS304 using WEDM

Abstract

ABSTRACT Wire electrical discharge machining (WEDM) is an outstanding variety of EDM processes in which the tool is a wire electrode. The medical, electronics, tool, and die industries use stainless steel 304 (SS304). However, there are traditionally many complications that manufacturers face, while machining SS304. Also, the creation of 3D shapes using WEDM is challenging. Due to difficulties in normal machining and producing 3D profiles using conventional machining of SS304, this research aims to utilize the application of WEDM for creating complex shapes or products with top as square and bottom as rectangular shape to get a rectangular frustum. A ϕ 0.25 mm brass wire was used, and experiments were conducted as per L9 array. Further, the determination of the best process parameter (Ton, Toff, Voltage, current) combination for achieving the highest MRR, hardness, and minimal surface roughness (Ra) and kerf with analysis of machined surfaces using an SEM microstructure image was tried. The results indicated that MRR and Ra values varied from 7.05 to 47.29 mm3/min and 1.251 to 2.019 µm, respectively. Furthermore, the kerf ranged from 0.294 to 0.475 mm and hardness started at 164 to 233 HV. To optimize WEDM results Grey relational analysis (GRA) was utilized.