Abstract
DC53 is considered as superior steel grade by die and mold making industries as compared to D2 and D3 steel due to its excellent mechanical characteristics like high hardness, wear resistance and strength. DC53 steel finds applications in making stamping dies, punches and cutting tools. In wire electric discharge machining (WEDM) process, gamma phase coated wire offers superior machining performance over uncoated brass and zinc coated electrode wires. This work was performed to study the effect of machining variables like sparks on duration, sparks off duration, arc-on time, and servo voltage on response variables, namely kerf width (KW), cutting speed (CS), material removal rate (MRR), and surface roughness (Ra) for WEDM of DC53 steel. Taguchi L18 orthogonal array was used for experimental design. Analysis of variance showed that sparks on duration is the most significant factor affecting KW, CS, and MRR with percentage contribution of 48.25 %, 80.21 %, and 45.21 %, respectively. Optimal set of machining parameters resulted in 14.02 % improvement in MRR and 19.24 % reduction in workpiece surface roughness. Moreover, gamma phase coated wire was found to have 30–35 % faster cutting rate as compared to uncoated brass wire.
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