EFFECT OF PROCESS PARAMETERS ON SURFACE ROUGHNESS AND DIMENSIONAL ACCURACY IN WIRE CUT ELECTRO DISCHARGE MACHINING

摘要

Wire electrical discharge machining (WEDM) has been found to be an extremely potential electro-thermal process in the field of conductive material machining. Owing to high process capability it is widely used in manufacturing of cam wheels, special gears, stators for stepper motors, various press tools, dies and similar intricate parts. This paper investigates the effect of process parameters like pulse on time, pulse off time, spark gap voltage, peak current and wire tension on surface roughness and dimensional accuracy. In order to evaluate the effect of selected process parameters, the Response Surface Methodology (RSM) is used to formulate a mathematical model which correlates the independent process parameters with the desired surface roughness and dimensional accuracy. The central composite rotatable design has been used to conduct the experiments. The analysis of results indicates that the pulse on time, pulse off time and servo voltage have a significant effect on surface roughness where as pulse on time, servo voltage, peak current and wire tension have a significant effect on dimensional accuracy.