Analysis of WEDM Process Parameters on Surface Roughness and Kerf using Taguchi Method

Abstract

In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap.

Electro-discharge machining of alumina: Investigation of material removal rate and surface roughness

“…In this case, a higher tool wear rate (TWR) and lower assisting electrode wear rate (AEWR) are obtained, along with higher crater volume and depth when higher capacitance and peak voltage are applied [4]. It is also observed that surface roughness increases with the increase of discharge current [2,8]. However, EDM of Al2O3 is found to be more difficult to machine because of the unsteady formation of electrically conductive layers on workpiece surface during the machining process [5,13].…”

“…Furthermore, higher pulseon time increased the plasma channel diameter which minimised both energy density and impulsive force. The reduction in impulsive force resulted in poor flushing of the melted debris which eventually formed a recast layer on the EDMed surface [2,21]. However, low pulse-on time with moderate peak current produced a plasma channel with higher energy density which can create a less rough surface [19,20].…”

“…Since electro-discharge machining (EDM) is a precise material removal process, it has been popularly applied for the machining of conductive materials with a minimum of 0.10 S.cm -1 electrical conductivity [1,2]. Electrical conductivity of selected materials is shown in Table 1 and the physical properties of Al2O3 are listed in Table 2.…”

Dimensional Accuracy in Dry Micro Wire Electrical Discharge Machining

“…Compressed air [36] was used as the dielectric fluid. The experimental parameters are listed in Table 1 were selected based on the capability of the machine, type of machining material, and tool material [3].…”

“…The demand in fabricating complex micro parts with high accuracy using electrical discharge machining (EDM) is increasing especially in biomedical, electronics, and aerospace industry [1][2][3][4]. EDM is preferable due to a non-contact machining operation where electrical energy is used to produce a series of discrete sparks between the tool electrode and the workpiece [5][6][7][8].…”