Experimental Investigations and Optimization of Machining Parameters on Alloy 10100 OFE/OFHC by Wire EDM

摘要

In this paper, to derive best operating inputs in order to attain best output, the influential parameters and their interactions need be studied, as some variables are basically contradictory in nature. The experiments were conducted in Taguchi L9 orthogonal array, with four levels of input parameters The various input machining parameters are cutting speed, pulse on/off time, spark gap voltage and input current have been tested to reveal the outputs on material removal rate (MRR) and Surface Roughness (Ra) of oxygen-free electrolytic/oxygen free high conductivity copper (OFE/OFHC10100) rods taken as work piece and X-cut wire of 0.2mm dia. as electrode wire using these variables as one time approach. Alloy 101 OFE/OFHC copper plate has high electrical and thermal conductivity with a very high resistance to hydrogen embrittlement. During experimentation, the material removal rate (MRR) directly increases with increase in pulse on time (T ON) and peak current (IP), while decreases with increase in pulse off time (T OFF) and servo voltage (SV). The level of importance of the machining parameters on the workpiece of surface roughness is determined by using analysis of variance (ANOVA). This work helps to understand the significant process parameters and interaction of WEDM process in machining of OFHC 10100.