International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025
p-ISSN: 2395-0072
www.irjet.net
Experimental investigation & optimization of Wire Electrical Discharge Machining (WEDM) Parameter for Material Removal Rate (MRR) in Machining of AISI D3 Tool Steel Dastageer R. Jamadar 1, Naim N. Mulla2, Amol A. Patil3, Vaishnavi V. Varape4,Anuradha P. Magdum5 1,2,3,4 UG Student, D. Y. Patil Technical Campus , Faculty of Engineering and Management, Talsande, Kolhapur, Maharashtra, India 5, Assistant Professor, D.Y.Patil Technical Campus , Faculty of Engineering and Management, Talsande, Kolhapur, Maharashtra, India ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - This study investigates the effects of key process
The wire electrode, usually made of brass, copper, or a brasszinc alloy, ranges in thickness from 0.001 to 0.014 inches and is fed from a spool. As the wire moves along a programmed path, the sparks progressively erode the workpiece, creating the desired shape or cut.
parameters in Wire Electrical Discharge Machining (WEDM) on the Material Removal Rate (MRR) during the machining of AISI D3 tool steel. Using a one-variable-at-a-time (OVAT) approach and Taguchi-based L9 orthogonal array for experimental design, the influence of pulse on time (TON), pulse off time (TOFF), peak current (IP), and wire feed rate (WF) was evaluated. Experimental trials were conducted on an ELECTRONICA SPRINTCUT machine using 0.18 mm zinccoated brass wire and deionized water as the dielectric medium. Analysis of Variance (ANOVA) identified pulse on time and wire feed rate as the most significant contributors to MRR variation. A regression model was developed to predict MRR with high accuracy (R² = 94.17%). Results reveal that increasing TON and TOFF enhances MRR, while higher WF and IP tend to reduce it. These findings provide a basis for optimizing WEDM parameters to improve machining efficiency of hard tool steels like AISI D3.
The dielectric fluid plays a crucial role in the Wire EDM process. It acts as an insulator between the wire and the workpiece until sufficient voltage is applied to ionize it, allowing a controlled spark to occur. Furthermore, the pressurized flow of the dielectric fluid through top and bottom flushing nozzles effectively removes the eroded particles (chips) from the cutting zone, preventing short circuits and ensuring efficient machining. The continuous flow of the dielectric also dissipates the heat generated by the sparks, preventing thermal expansion of the work piece, which could compromise dimensional and positional accuracy. To maintain consistent machining conditions and accuracy, the dielectric fluid is continuously filtered to remove suspended solids and passed through a chiller to maintain a constant temperature.
Key Words: Wire EDM, Material Removal Rate, AISI D3 Tool Steel, Pulse On Time, Taguchi Method, ANOVA
In essence, Wire EDM removes material through spark erosion, making it essential for the workpiece to be electrically conductive. The process allows for the creation of intricate and complex shapes with high precision and surface finish, with the volume of material removed being directly related to the desired cutting speed and surface quality.
1.INTRODUCTION Wire Electrical Discharge Machining (Wire EDM) is a nontraditional machining process that utilizes a series of rapid, controlled electrical discharges (sparks) to erode electrically conductive materials. This process occurs between a thin, continuously moving wire electrode and the work piece, separated by a minute spark gap filled with an insulated dielectric fluid, typically de-ionized water.
2. LITERATURE SURVEY This compilation summarizes several studies exploring the influence of Wire Electrical Discharge Machining (WEDM) parameters on performance. Researchers have investigated how varying pulse-on time, pulse-off time, voltage, current, wire feed, wire tension, and flushing pressure affect Material Removal Rate (MRR), surface roughness, and kerf width.
During the machining operation, high-frequency pulses of alternating or direct current are discharged from the wire to the work piece. These discharges, occurring at rates exceeding one hundred thousand times per second and lasting less than a microsecond, generate intense heat, estimated between 15,000° to 21,000° Fahrenheit. This extreme heat causes localized melting and vaporization of a tiny volume of material from both the workpiece and a small portion of the wire electrode.
© 2025, IRJET
|
Impact Factor value: 8.315
M Siva Kumar et al. [2]utilized Taguchi's L18 array to study AISI D3 steel, finding that increased pulse-on time, current, and voltage enhanced MRR, while pulse-off time had
|
ISO 9001:2008 Certified Journal
|
Page 1076