Experimental Investigation And Determine The Influence Of Process Parameters On Surface Quality In Wire Cut Edm

Abstract

Wire Cut Electric Discharge Machining process with a thin wire as an electrode transforms electrical energy to thermal energy for cutting materials. WEDM is considered as a unique adoption of the conventional EDM process, which uses an electrode to initialize the sparking process. However, WEDM utilizes a continuously travelling wire electrode made of thin copper, brass or tungsten of diameter 0.05-0.30 mm, which is capable of achieving very small corner radii. The wire is kept in tension using a mechanical tensioning device reducing the tendency of producing inaccurate parts. During the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the work piece and the wire, eliminating the mechanical stresses during machining.              Wire-cut Electrical Discharge Machining (WEDM) is extensively used in machining of conductive materials producing intricate shapes with high accuracy. This study exhibits that WEDM process parameters can be altered to achieve betterment of Material removal rate (MRR), Surface Roughness (SR) and Electrode Wear. The objective of our project is to investigate and optimize the potential process parameters influencing the SR and Electrode Wear while machining of aluminum alloys using WEDM process. This work involves study of the relation between the various input process parameters like Pulse-on time (Ton), Pulseoff time(Toff),  Pulse  Peak Current(IP), Wire material, Work piece material and process variables. Based on the chosen input parameters and performance measures L-9 orthogonal array is selected to optimize the best suited values for machining for aluminum alloys by WEDM