Optimization Of Wire Cut Electrical Discharge Machining With Respect To Cut Characteristics

Abstract

Wire electrical discharge machining (WEDM) process has gained the popularity for newlinemachining difficult-to-cut materials such as nickel-based alloys and titanium alloys. It is an newlineelectro-thermal nonconventional machining process. In this process, material erodes by newlineseries of discrete electric sparks between the wire electrode and the workpiece. The newlinetemperature of spark reaches up to 12,000°C that causes melting and vaporization of the newlinematerial. The debris produced in the process is flushed away by the flowing dielectric fluid newlinewhich is continuously circulating. newlineWith the help of WEDM complex, contoured shapes in the exact dimensions newlinerequired can be machined. Since there is no direct contact between the workpiece and wire newlinethus eliminating the mechanical stresses produced during machining. Minimal machining newlineforces allow it to achieve tight tolerances of up to 2 microns. newlineSeveral problems such as chatter formation, lower cutting speed, notch wear at the newlinetool nose, abrasive wear of the tool, high diffusion wear rate, spalling on the tool rake face, newlinedegradation of tool material by seizure and cratering, high temperature at the tool tip and of newlinehigher mechanical stresses occurs during conventional machining of nickel-based alloys and newlinetitanium alloys. newline