Experimental investigation on die corner accuracy for wire electrical discharge machining of Monel 400 alloy

Abstract

The experimental research presented in this article explores the wire electrical discharge machining of Monel 400 alloy. An L-18 orthogonal array has been used for experimentation by considering machine controllable factors (i.e. wire tension, pulse-on time, pulse frequency, peak current and servo voltage) and machine uncontrollable factors (namely flushing nozzle height, workpiece thickness and corner angle) as process parameters. Using Taguchi methodology, the influence of the process parameters on the responses, such as material removal rate, surface roughness and corner error, were studied. The impact of pulse parameters modification in corner accuracy improvement has been analyzed. Finally, using Taguchi’s additive model predictions and Pareto optimality approach, a sample technology table for a specific machining condition has been reported for ready use.

Enhancing die corner accuracy through trim cut in WEDM

“…3) at the die is much higher than the corner error at the punch, as illustrated by Sarkar et al [11]. Nevertheless, very limited research [9,10] has been reported on die corner accuracy aspects in WEDM. In this research study, an attempt has been made in the view of enhancing die corner accuracy by adopting trim cutting operation.…”

“…The WEDM is one of the best cost-effective methods that eliminate secondary operations [1] in producing high-precision dies and tools. Though many precision dies are manufactured using WEDM, very little attempts have been reported [2][3][4][5][6][7][8][9][10] on corner cutting and corner accuracy aspects in WEDM. Achieving a sharp corner for the customer-specified surface and accuracy features is a matter of grave concern in the WEDM process which can be addressed through an appropriate process design by adopting trim cutting operation.…”

“…But, Selvakumar et al [10] have proved that the parameter modification strategy in the presence of a larger wire lag arising due to higher workpiece thickness, acute corner angle, and higher flushing nozzle height yields poor results in improving corner accuracy. In order to enhance the die corner accuracy for the stated machining condition [10], an attempt has been made through trim cutting operation.…”

“…But, Selvakumar et al [10] have proved that the parameter modification strategy in the presence of a larger wire lag arising due to higher workpiece thickness, acute corner angle, and higher flushing nozzle height yields poor results in improving corner accuracy. In order to enhance the die corner accuracy for the stated machining condition [10], an attempt has been made through trim cutting operation. Despite that a few research works reported on trim cutting operation, the present work is very unique as it has included corner accuracy aspects which were mostly ignored by the past researchers [2,12,13].…”

An Experimental Study of Aerospace Material during Fabrication of V Groove using WEDM

“…It was concluded that average surface was improved in liquid nitrogen cooling of the electrode [8]. Experimental study has been done to investigate the influence of process parameters for MRR, SR, Kerf, over cut and corner accuracy by machining of advanced materials by using Taguchi and ANOVA method [9][10][11][12].…”