Abstract
In this article, the wire electrical discharge machining of different heights of die steel workpieces has been carried out for different control strategies, i.e. proportional control mode, constant speed mode, constant voltage mode, and constant area feeding mode. It is very crucial to understand the thermo-mechanical aspect of the machining gap during machining of changing job height. For the efficient machining of variable thickness of jobs, these observations are extremely essential. Here, it is observed how job height influences cutting speed, surface roughness, kerf width, gap voltage, gap current, input power, and specific energy consumption under these control strategies. So far, very little research work has been reported in this area. Thus, it is quite imperative to carry out an intensive research study of wire electrical discharge machining (WEDM) during machining of different job thickness under those control strategies. An attempt has been made to understand the nature of variation of these important response parameters. The average and variance of some of the most influential parameters, i.e., cutting speed, surface finish, and kerf width were also calculated. Along with this, to predict the different important response parameters, i.e., cutting speed, surface finish, and kerf width for any given height job under any specified control strategy, regression analysis was carried out.
Similar content being viewed by others
References
Jain VK (2002) Advanced machining processes. Allied Publishers Pvt. Ltd, Mumbai
Liao YS, Huang JT, Su HC (1997) A study on the machining—parameters optimisation of wire electrical discharge machining. J Mater Process Technol 71:487–493. doi:10.1016/S0924-0136(97)00117-9
Spedding TA, Wang ZQ (1997) Study on modeling of wire EDM process. J Mater Process Technol 69:18–28. doi:10.1016/S0924-0136(96)00033-7
Karthikkeyan R, Lakshmi Narayanan PR, Naagarazan RS (1999) Mathematical modeling for electric discharge machining of aluminum–silicon carbide particulate composites. J Mater Process Technol 87:59–63. doi:10.1016/S0924-0136(98)00332-X
Sarkar S, Mitra S, Bhattacharyya B (2005) Parametric optimisation of wire electrical discharge machining of γ titanium aluminide alloy through an artificial neural network model. Int J Adv Manuf Technol 27:501–508. doi:10.1007/s00170-004-2203-7
Tosun N, Cogun C, Tosun G (2004) A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method. J Mater Process Technol 152:316–322. doi:10.1016/j.jmatprotec.2004.04.373
Raksiri C, Chatchaikulsiri P (2010) CNC wire-cut parameter optimized determination of the stair shape workpiece. World Acad Sci Eng Technol 70:101–106
Malleswara Rao SS, Parameswara Rao Ch VS (2013) Parametric evaluation for machining die steel with WEDM. IJSRP 3:1–5, 10.1.1.300.5755
Sarkar S, Mitra S, Bhattacharyya B (2005) Geometry analysis and corner compensation strategy in WEDM for enhanced profile accuracy. In: Proceeding of 4th National Conference on Precision Engineering (COPEN). Jadavpur University, Kolkata, pp 154–160
Kanlayasiri K, Boonmung S (2007) An investigation on effects of wire EDM machining parameters on surface roughness of newly developed DC53 die steel. J Mater Process Technol 187–188:26–29. doi:10.1016/j.jmatprotec.2006.11.220
Scott D, Boyina S, Rajurkar KP (1991) Analysis and optimization of parameter combinations in wire electrical discharge machining. Int J Prod Res 29:2189–2207. doi:10.1080/00207549108948078
Lin CT, Chung IF, Huang SY (2001) Improvement of machining accuracy by fuzzy logic at corner parts for wire EDM. Fuzzy Set Syst 122:499–511. doi:10.1016/S0165-0114(00)00034-8
Liao YS, Yan MT, Chang CC (2002) A neural network approach for the on-line estimation of workpiece height in WEDM. J Mater Process Technol 121:252–258. doi:10.1016/S0924-0136(01)01252-3
Mori T (1990) The new experimental design: Taguchi’s approach to quality engineering. ASI press, Dearborn
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Samanta, A., Sekh, M. & Sarkar, S. Influence of different control strategies in wire electrical discharge machining of varying height job. Int J Adv Manuf Technol 100, 1299–1309 (2019). https://doi.org/10.1007/s00170-016-9045-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9045-y