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The IUP Journal of Mechanical Engineering
The Effect of Process Parameters on the Performance Characteristics of Wire Electrical Discharge Machining of AISI d3 Tool Steel
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In this paper, zinc coated diffused brass wire and plain brass wire have been used as cutting tools and AISI D3 as workpieces. The input process parameters considered were wire type, pulse on time (Ton), pulse off time (Toff) and servo voltage. Taguchiís L18 orthogonal array has been used for the design of experiments. The process performance was measured in terms of optimization of Material Removal Rate (MRR) and Surface Roughness (Ra). It was observed that pulse-on time and pulse-off time were the two most significant factors affecting the MRR and Ra. MRR has increased with increase in pulse-off time, whereas Ra decreased with increase in pulse-on time. The formation of craters and debris was studied according to the selected parameters of the experiment in Scanning Electron Microscopes (SEM) analysis.

 
 

Since the invention of Electrical Discharge Machining (EDM) in the late 1940s, it has been used for manufacturing of dies, molds, surgical equipments and parts of automobiles and airplanes (Ho et al., 2004; Singh et al., 2014; and Shinge et al., 2017). The electric discharges between tool and workpiece remove the material with erosion from the surface. It is used to machine hard materials which are difficult to machine with conventional machining processes (El-Taweel and Hewidy, 2013; Singh et al., 2013; Singh and Pradhan, 2014; and Santhanakumar et al., 2017). The input parameters of EDM process are very important for optimizing the machining process (Prabhu and Vinayagam, 2010; Kubade et al., 2015; and Das et al., 2016).

 
 

Mechanical Engineering Journal, Wire Electrical Discharge Machining (WEDM), ANOVA, Surface Roughness (Ra), S/N Ratio, Process parameters