Abstract
Wire electrical discharge machining (WEDM) is one of the most important nontraditional machining process that is well-known for cutting difficult to machine materials. The wire electrode along with machining parameters control the WEDM process. This research work focuses on optimizing WEDM parameters using Taguchi technique to minimize wire rupture. Experiments have been done using the L18 orthogonal array. Each experiment is repeated three times to ensure accurate readings of the wire rupture. The statistical methods of signal to noise ratio (S/N ratio) is applied to study effects of peak current, pulse width, charging time, wire speed, and wire tension on wire rupture. As a results, the peak current, pulse width, and wire tension have the most significant effect on wire rupture followed by charging time and wire speed. The developed analysis can be used in the metal cutting field to identify the optimum machining parameters for less wire rupture.
Highlights
Wire electrical discharge machining (WEDM) is one of the most commonly known and applied nonconventional machining processes in today’s industrial practice
The effects of machining parameters related to power supply, wire electrode were investigated on wire rupture or wire loss (WL)
The optimum cutting conditions, which were the peak current of 16 A, the pulse width of 0.2 μs, the charging time of 1.3 μs, the wire speed of 11 m/min and the wire tension of 10.5 N were obtained for the wire rupture
Summary
Wire electrical discharge machining (WEDM) is one of the most commonly known and applied nonconventional machining processes in today’s industrial practice. WEDM is used to cut any electrically conductive materials. WEDM facilitates machining complicated shapes that cannot otherwise be achieved with conventional machining processes like turning, milling, and grinding [1]. WEDM is an electro-thermal production process, in which a thin, single-strand metal wire in conjunction with deionized water cuts through metal using heat from electrical sparks. Wire electrode is one of the most important components of cutting process in WEDM. WEDM Machining performance depends on the electrical, mechanical, physical, and geometrical properties of the wire electrode. Other WEDM factors including the mechanical theory, machine intelligence, type of pulse generator, and dielectric flushing system affect machining performance
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