Analysis of the Effect of Wire Electric Dischage Machining Process Parameters for the Formation of High Speed Steel Form Tool

Abstract

The use of form tools is growing in industry, owing to their inherent advantage of improving productivity. However, the accurate formation of form tool profile is a really tedious task. In this research work, wire electric discharge machining (WEDM) process has been used for the generation of a form tool. Pulse on-time, pulse off-time, servo voltage, wire tension, flushing pressure have been considered as input parameters, whereas tool geometry (clearance angle, included angle), surface roughness and material removal rate are the selected responses. Response surface methodology (RSM) (Box Bhenken experimental design) technique has been used for design of experiments. Analysis of Variance (ANOVA) has shown that pulse on-time and pulse off-time are the two influential control factors for material removal rate (MRR), surface roughness (Ra), clearance angle and included angle. Contour plot analysis has been performed to find out the optimal ranges of the most influential control factors for each response characteristics.

Surface Topography of Inconel 718 Alloy in Finishing WEDM

“…The distribution of the Sa parameter is similar to that of the Ra parameter. Ishfaq et al [36] also noted that the increase in surface quality of HSS form tool made by WEDM is obtained for lower electric parameters.…”

Comparative Analysis of Different WEDM Strategies Applied to Cut WC-Co Cemented Carbides

“…Measured stresses in aluminium alloys increased by heat generated during EDM. Authors of [3] analysed wire electrical discharge machining application for the generation of steel, form tool. Time parameters, voltage, electrode tension, flushing pressure were varied whereas tool geometry (clearance angle, included angle), surface roughness and MRR (Material Removal Rate) were the measured responses.…”

Effects of Wire-EDM Machining Variables on Surface Roughness of D2 Steel Material

“…Bikash et al [9] had been studied the performance of WEDM while machining of H21 tool using RSM and particle swarm optimization (PSO). They considered pulse on time, pulse off time, current, gap voltage and wire tension, as process parameters.…”