Article: Optimisation of process parameters for gap current in wire electrical discharge machining Journal: International Journal of Manufacturing Technology and Management (IJMTM) 2012 Vol.25 No.1/2/3 pp.161 - 175 Abstract: Electrical discharge wire cutting, more commonly known as wire electrical discharge machining (WEDM), is a spark erosion process used to produce complex two- and three-dimensional shapes through electrically conductive work pieces by using wire electrode. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilising the widely accepted non-contact technique of material removal. In this paper, the various process parameters of WEDM like pulse on time (TOON), pulse off time (TOFF),spark gap set voltage (SV), peak current (IP), wire feed (WF) and wire tension (WT) have been optimised to get their maximum impact on gap current (Ig) so as to obtain maximum material removal rate for hot die steel (H-11) material. Experimental investigation based on Taguchi's L-27 orthogonal array has been done. Signal-to-noise (S/N) ratio, analysis of variance (ANOVA) and various plots are generated to predict the optimal set of process parameters to maximise the gap current. The confirmation experiments have also been conducted to validate the results obtained by Taguchi technique. Inderscience Publishers - linking academia, business and industry through research

Title: Optimisation of process parameters for gap current in wire electrical discharge machining

Authors: Rohit Garg; Hari Singh

Addresses: Mechanical Engineering Department, Indus Institute of Engineering and Technology, 15 Km Stone, Jind-Rohtak Road, Kinana, Jind, Haryana, India. ' Mechanical Engineering Department, National Institute of Technology, Kurukshetra, Haryana, India

Abstract: Electrical discharge wire cutting, more commonly known as wire electrical discharge machining (WEDM), is a spark erosion process used to produce complex two- and three-dimensional shapes through electrically conductive work pieces by using wire electrode. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilising the widely accepted non-contact technique of material removal. In this paper, the various process parameters of WEDM like pulse on time (TO_ON), pulse off time (T_OFF),spark gap set voltage (SV), peak current (IP), wire feed (WF) and wire tension (WT) have been optimised to get their maximum impact on gap current (Ig) so as to obtain maximum material removal rate for hot die steel (H-11) material. Experimental investigation based on Taguchi's L-27 orthogonal array has been done. Signal-to-noise (S/N) ratio, analysis of variance (ANOVA) and various plots are generated to predict the optimal set of process parameters to maximise the gap current. The confirmation experiments have also been conducted to validate the results obtained by Taguchi technique.

Keywords: wire EDM; electrical discharge machining; WEDM; gap current; hot die steel; analysis of variance; ANOVA; manufacturing technology; optimisation; Taguchi methods; electro-discharge machining; orthogonal arrays; signal-to-noise ratio; analysis of variance; ANOVA; material removal rate; MRR.

DOI: 10.1504/IJMTM.2012.047725

International Journal of Manufacturing Technology and Management, 2012 Vol.25 No.1/2/3, pp.161 - 175

Published online: 26 Nov 2014 *

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Title: Optimisation of process parameters for gap current in wire electrical discharge machining

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