IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 09, 2015 | ISSN (online): 2321-0613
Optimization of Process Parameters of Wire-Cut Electric Discharge Machine using Tungsten Die Tool Steel using Taguchi Method Mr. Harish Kumar Sharma1 Mr. Deepak Gupta2 1,2 Department of Mechanical Engineering 1,2 Galaxy Global Educational Trusts Group of Institutions Ambala Abstract— Wire-cut Electric Discharge Machine (WEDM) process is one of the most widely used non-traditional machining processes in current manufacturing. It involves the removal of metal by discharging an electrical current from a pulsating DC power supply across a thin interelectrode gap between the tool and the work piece. It is most commonly used for machining hard and difficult to machine materials with very close tolerances. This work presents an investigation on effect and optimization of machining parameters for cutting speed, die width. Surface roughness, in wire electric discharge machining. Tungsten die tool steel is used for this research. It is commonly used for hot working dies and tooling such as die casting, extrusion and hot forming of parts. It has been observed that effect of each process parameter for optimization of each performance measure is different. MINITAB 15 software is also used to find the effect of each parameter on response characteristic and to predict the setting of control parameters. Key words: Wire-Cut Electric Discharge Machine, Tungsten Die Tool I. INTRODUCTION Wire electrical discharge machining or WEDM is a metal working process, with the help of which a material is separated from a conductive work piece, by the process called electrical erosion. The wire is not in touch with the conductive work piece. The wire electrode generates a path on the work piece, which is slightly larger than the wire. Mostly a 0.010 inch (0.25 mm) wire is used which made a 0.013 to 0.014 inch gap. The wire electrode once passed through and cannot be reused. The wire electrode and the work piece are held at an accurately controlled distance from one another, which are dependent on the operating condition and refer to as spark gap. This gap prevents the mechanical contact of tool and work. The movement of wire is controlled numerically using computer to achieve the dimensional shape and accuracy of the desired value.
instantaneously, temperature reaches up to above 10000 degree centigrade, the eroded work piece is cooled down swiftly in working liquid and flushed away. Wire electrode is generally made up of copper, brass or tungsten of diameter 0.05mm to 0.3mm, which is capable to achieve a very small corner radii. When the equipoise voltage is applied across the two electrode separated by a dielectric fluid, the latter starts breaking down. The electrons, so liberated are accelerated in presence of the electric field and starts colliding with the dielectric molecules, causing the latter to be robbed off their electrons. III. EXPERIMENTAL PROCEDURE Experiments were conducted to study the effects of the various machining parameters on WEDM working. Studies have been undertaken to investigate the effects of the important parameters viz., Discharge current, pulse on time, pulse off time, wire speed and wire tension on cutting speed, surface roughness and die width. A. Work Piece Electrode The work piece material is used in this investigation was H21 die tool steel. Composition of H21 die tool steel is C= 0.30%, Mn= 0.30% , Si=0.20% ,Cr= 3.60%, Ni=0.3%, W= 8.5%, V= 0.40%,Cu=0.25,P=0.03 and S=0.03. A H21 die tool steel plate of size 200x50x20 (l x b x w) could reach the HB300 at the temperature of 650 C.
II. PRINCIPLE OF WEDM WEDM puts impulse voltage between the electrode wire and work piece through impulse source, controlled by using servo system, to get a certain desired gap, and realize impulse discharging in the working liquid between electrode wire & work-piece. Numerous tiny small holes appear due to erosion of impulse discharging and therefore get the required shape of work-piece (as shown in figure 1.1) Electrode wire is connected to the cathode of impulse power source, and work piece is connected to the anode of impulse power source. When the work piece is approaching insulating liquid and gap between them getting small to a certain value, insulating liquid was broken through; very shortly, discharging channel are formed, and electrical discharging happen. This result in high temperature
Fig. 1: The Sprint-cut WEDM Density 8.19g/cm3 Poisson's ratio (25°C) 0.27-0.30 Thermal conductivity 27.0 W/mK Specific heat (Cal/goC) 0.110 Table 1: Physical Properties. All the six faces of tool steel plate are grinded to remove the burrs and rusts so that wire moves smoothly throughout the work piece. H-21 die tool steel is also characterized by its high dimensional stability after hardening and tempering, high compressive strength. The success of a metal forming tool is depending on optimizing all the factors which is affecting its performance. Usually,
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