Abstract

Engineering industry has made tremendous growth in its manufacturing fields in the last decade but still the modern machines are not utilized up to the desired level. Wire electrical discharge machining (WEDM) is one such sophisticated machining process used in industry, which is a high-speed cutting and high-precision machining to realize productivity and improved accuracy for all manufacturing parts. Optimisation of the operating parameters of WEDM will result in efficiency with regard to higher surface finish and maximum material removal rate. The present investigation of the cutting performance on die steel with different parameters such as pulse on time, pulse off time, servo voltage, wire feed, current and cutting speed were involved to determine by which using wire electric discharge machining(WEDM) process. The shape of the wire and base material dimensions of brass wire 0.25mm diameter and AISI D2 steel with 100× 100 × 10 mm were carried out. The cutting performance outputs considered in this study are material removal rate (MRR), Kerf width and surface roughness (Ra). Experiments were carried out under Taguchi's L16 orthogonal array under different conditions of parameters. An optimal combination of WEDM parameters for proper machining of AISI D2 steel to achieve better surface roughness and Materials Removal Rate (MRR) is achieved in this investigation.

Highlights

  • Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by means of electric spark erosion

  • The effects on material removal rate (MRR), surface roughness, and kerf width are determined by varying Wire Electro Discharge Machining (WEDM) essential parameters such as peak current (A), Pulse on time (Ton), Pulse off time (Toff) and gap voltage (V).The experimental data were transferred to grey relational grade and were assessed using analysis of variance (ANOVA) for determining the significant and optimal combinational levels of machining parameters to achieve multiple performance characteristics

  • In WEDM optimal machining parameters were established for achieving high Material Removal Rate (MRR), good surface roughness and kerf width for difficult to machine materials

Read more

Summary

Introduction

Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by means of electric spark erosion. The metal-removal process is performed by applying a pulsating (ON/OFF) electrical charge of high-frequency current through the electrode to the work piece. This removes (erodes) very tiny pieces of metal from the work piece at a controlled rate. The most significant process parameters which affect the machining performance are MRR, SR in WEDM process reported by Miller et al [4] and the properties affecting the Konda et al [5] WEDM performance due to work piece material and di-electric fluid, machining parameters and component geometry. The aim of this work a study of material removal mechanism in Wire Electro Discharge Machining (WEDM) process and optimization of performance characteristics has been undertaken keeping into consideration the following problems such as pulse on time, pulse off time, voltage, current and other machining parameters.

Selection of the Work Piece
Process Parameters Selection
Taguchi Design
Results and Discussion
Conclusions
Full Text
Published version (Free)

Talk to us

Join us for a 30 min session where you can share your feedback and ask us any queries you have

Schedule a call