Advertisement

KSME International Journal

, Volume 17, Issue 6, pp 816–824 | Cite as

The effect of the cutting parameters on performance of WEDM

  • Nihat Tosun
Article

Abstract

In this study, variations of cutting performance with pulse time, open circuit voltage, wire speed and dielectric fluid pressure were experimentally investigated in Wire Electrical Discharge Machining (WEDM) process. Brass wire with 0.25 mm diameter and AISI 4140 steel with 10 mm thickness were used as tool and work materials in the experiments. The cutting performance outputs considered in this study were surface roughness and cutting speed. It is found experimentally that increasing pulse time, open circuit voltage, wire speed and dielectric fluid pressure increase the surface roughness and cutting speed. The variation of cutting speed and surface roughness with cutting parameters is modeled by using a regression analysis method. Then, for WEDM with multi-cutting performance outputs, an optimization work is performed using this mathematical models. In addition, the importance of the cutting parameters on the cutting performance outputs is determined by using the variance analysis (ANOVA).

Key Words

Wire EDM Cutting Performance ANOVA Regression Analysis 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. Cogun, C., Akaslan, S., 2002, “The Effect of Machining Parameters on Tool Electrode Edge Wear and Machining Performance in Electric Discharge Machining (EDM),”KSME International Journal, Vol. 16 No. 1, pp. 46–59.Google Scholar
  2. Davim. J. P. and Antonio, C. A. C., 2001, “Optimal Drilling of Particulate Metal Matrix Composites Based on Experimental and Numerical Procedures,”International Journal of Machine Tools & Manufacture, Vol. 41, pp. 21–31.CrossRefGoogle Scholar
  3. Doyle, L. E., Keyser, C. A., Leach, J. L., Schrader, G. F. and Singer, M. B., 1985,Manufacturing Processes and Materials for Engineering, Third edition. Prentice-Hall Inc., USA.Google Scholar
  4. Fuller, J. E., 1989,Machining: Electrical Discharge Machining, Metals Handbook, ASM International, Ninth edition, Ohio. USA Vol. 16, pp. 557–564.Google Scholar
  5. Kim, C. H. and Kruth, J. P., 2001, “Influence of the Electrical Conductivity of Dielectric on WEDM of Sintered Carbide,”KSME International Journal, Vol. 15, No. 12, pp. 1676–1682.Google Scholar
  6. Kozak, J., Rajurkar, K. P. and Wang, S. Z., 1994, “Material Removal in WEDM of PCD Blanks,”Journal of Engineering for Industry- Transactions of the ASME, Vol. 116, No. 3, pp. 363–369.CrossRefGoogle Scholar
  7. Liao, Y. S., Huang, J. T. and Su, H. C., 1997, “A Study on the Machining-parameter Optimization of Wire Electrical Discharge Machining,”Journal of Materials Processing Technology, Vol. 71, pp. 487–493.CrossRefGoogle Scholar
  8. Lin, J. L., Wang, K. S., Yan, B. H. and Tarng, Y. S., 2000, “An Investigation into Improving Worn Electrode Reliability in the Electrical Discharge Machining Process,”The International Journal of Advanced Manufacturing Technology, Vol. 16, pp. 113–119.CrossRefGoogle Scholar
  9. Lok, Y. K. and Lee, T. C., 1997, “Processing of Advanced Ceramics Using the Wire-Cut EDM Process,”Journal of Materials Processing Technology, Vol. 63, No. 1-3, pp. 839–843.CrossRefGoogle Scholar
  10. Phadke, M. S., 1989,Quality Engineering Using Robust Design, Prentice-Hall, USA.Google Scholar
  11. Rajurkar, K. P. and Wang, W. M.. 1993, “Thermal Modeling and On-Line Monitoring of Wire- EDM,”Journal of Materials Processing Technology. Vol. 38, No. 1-2, pp. 417–430.CrossRefGoogle Scholar
  12. Ross, P. J., 1996,Taquchi Techniques for Quality Engineering, Second Edition, McGraw-Hill, USA.Google Scholar
  13. Rozenek, M., Kozak, J., DabroVwki, L. and LubkoVwki, K., 2001, “Electrical Discharge Machining Characteristics of Metal Matrix Composites,”Journal of Materials Processing Technology, Vol. 109, pp. 367–370.CrossRefGoogle Scholar
  14. Scott, D., Boyina, S. and Rajurkar, K. P., 1991, “Analysis and Optimization of Parameter Combinations in Wire Electrical Discharge Machining,”International Journal of Production Research, Vol. 29, No. 11, pp. 2189–2207.MATHCrossRefGoogle Scholar
  15. Spedding, T. A. and Wang, Z. Q., 1997, “Parametric Optimization and Surface Characterization of Wire Electrical Discharge Machining Process,”Precision Engineering, Vol. 20, No. 1, pp. 5–15.CrossRefGoogle Scholar
  16. Tarng, Y. S., Ma, S. C. and Chung, L. K., 1995, “Determination of Optimal Cutting Parameters in Wire Electrical Discharge Machining,”International Journal of Machine Tools and Manufacture, Vol. 35, No. 12, pp. 1693–1701.CrossRefGoogle Scholar
  17. Tosun, N., Cogun, C. and Pihtili, H., 2002, “The Effect of Cutting Parameters on Wire Crater Sizes in Wire EDM,”The International Journal of Advanced Manufacturing Technology, (in press).Google Scholar

Copyright information

© The Korean Society of Mechanical Engineers (KSME) 2003

Authors and Affiliations

  1. 1.Mechanical Engineering DepartmentFirat UniversityElazigTurkey

Personalised recommendations