In this article, the effect of cryogenic treatment on the brass wire electrode used in wire electrical discharge machining is investigated. Deep cryogenic (À184 C) treatment is given to the brass wire electrode. The microstructure and crystalline phase of deep and non-cryogenic treated brass wire electrodes is observed by scanning electron microscope and X-Ray diffraction. The experimental results show that the structure is more refined in deep cryogenic treatment as compared to non-cryogenic treatment. The electrical conductivity of deep electrode is greatly improved. The effect of deep cryogenic treatment on the brass wire electrode is also investigated for the performance of wire electrical discharge machining. Taguchi experimental design has been applied to investigate the optimal parameters for maximum material removal rate. The ANOVA analysis indicates that type of wire, pulse width, time between two pulses and wire tension are significant factors for maximization of material removal rate. The cryogenic treatment results in improved material removal rate.
In this paper, the effect of different wire electrodes used in wire electrical discharge machining (WEDM) on the machining characteristics of AISI D3 die steel has been presented. Three process parameters, namely type of wire (brass wire, zinc coated wire and composite wire), pulse on time and peak current have been considered. The process performance is measured in terms of cutting speed and surface roughness. The research outcome will identify the important parameters and their effect on performance characteristics while machining AISI D3 material with different wire electrodes. The analysis of variance (ANOVA) of multilevel factorial design indicated that all the selected parameters have significant effect on the performance characteristics. The study indicated the improvement in surface roughness with brass wire over other wires. Maximum cutting speed was obtained with composite wire as compared to zinc coated and brass wire. Additionally, scanning electron microscope (SEM) examination highlighted important features of machined work piece surface.
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