Abstract
Abstract. Tungsten carbide-cobalt (WC-Co) composite is a difficult-to-machine material owing to its excellent strength and hardness at elevated temperature. Wire electrical discharge machining (WEDM) is a best alternative for machining of WC-Co composite into intricate and complex shapes. Efficient machining of WC-Co composite on WEDM is a challenging task since it involves large numbers of parameters. Therefore, in present work, experimental investigation has been carried out to determine the influence of important WEDM parameters on machining performance of WC-Co composite. Response surface methodology, which is a collection of mathematical and experimental techniques, was utilised to obtain the experimental data. Using face-centered central composite design, experiments were conducted to investigate and correlate the four input parameters: pulse-on time, pulse-off time, servo voltage and wire feed for three output performance characteristics – cutting speed (CS), surface roughness (SR) and radial overcut (RoC). Using analysis of variance on experimental data, quadratic vs. two-factor interaction (2FI) models have been suggested for CS and RoC while two-factor interaction (2FI) has been proposed for SR. Using these mathematical models, optimal parameters can be determined easily for desired performance characteristics, and hence a trade-off can be made among different performance characteristics.
Highlights
Demand for tungsten carbide-cobalt (WC-Co) composite has been growing rapidly due to its excellent mechanical properties like high wear and corrosion resistance, which makes it most suitable for cutting tools, dies and other special wearresisting applications
Due to the low material removal rate and difficulty in machining of complex and intricate profiles in WC-Co composite, cost associated with conventional machining processes is very high
In order to achieve high productivity within specified tolerance on Wire electrical discharge machining (WEDM), selection of optimal process parameters plays a key role which depends on large numbers of variables such as composition and grain size of work material, machining parameters, wire electrode material, wire diameter, cutting conditions and work geometry etc. (Jangra et al, 2011)
Summary
Demand for tungsten carbide-cobalt (WC-Co) composite has been growing rapidly due to its excellent mechanical properties like high wear and corrosion resistance, which makes it most suitable for cutting tools, dies and other special wearresisting applications. Wire electrical discharge machining (WEDM) is a specialised form of electrical discharge machining (EDM) process which is potentially used to generate intricate and complex geometries in hard conductive materials without making any mechanical contact (Jangra et al, 2010). In order to achieve high productivity within specified tolerance on WEDM, selection of optimal process parameters plays a key role which depends on large numbers of variables such as composition and grain size of work material, machining parameters, wire electrode material, wire diameter, cutting conditions and work geometry etc. OMfadhidsacvhianregjaedeannedrMgyahodnavinintee-gritygoafteEtDheMineflduseuncrfeaocfeporfocess parameters and to develop the was found thjaadt t(h2e00s5u)rfsatucdeierdouthgehninesstsabisiliatyfuinncEtDioMn ooff tWwCo-mCoaicnopma-ramemteartsh,epmeaatkicaclurmreondtelasnfdor three performance characteristics posites This machining instability was mainly due to open namely cutting speed (CS), surface roughness (SR) and ragh peak cucrirrecnutit,asnhdo/rot rcilrocunigt apnudlasrecidnugrpautilsoens.rIonucrgehasseuirnfpaucleseadnudraa-bunddainalceovoefrcmutic(Rroo-Cc)raicnkWs EDM of WC-5.3 % Co composite.
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