Experimental Investigation and process parameter optimization of WEDM during profile cutting of AISI D3 Tool Steel

Abstract

Wirecut-Electrical discharge machining (WEDM) is one of the most newlinecost-effective and efficient ways to machine hard and electrically conductive newlinematerials. Wire EDM offers the additional benefit of accuracy in creating part newlineshapes. WEDM is a non-traditional machining process, usually adopted to cut newlinehard-to-machine materials, to achieve complex and intricate profiles with newlinehigher precision and dimensional accuracy, which are mostly desirable in newlinepresent industrial scenario. WEDM uses a wire electrode, for metal removal newlinealong with flushing of dielectric during machining process. WEDM is an newlineelectro-thermal machining process for electrically conductive materials. In newlineWEDM, the cutting tool (wire electrode) never touches the workpiece during newlinethe machining process. Wire EDM machining is more accurate than laser, newlineflame cut, or plasma and no cutting force is imparted by the process, due to newlinehigh precision and accuracy of machining, additional processing and finishing newlineof parts after machining is eliminated.From the analysis of MRR and SR using different wires and comparing newlinethe output using GRA and cuckoo search algorithm, it was observed that the newlineperformance of molybdenum wire as electrode outplays the performance of newlineother two wires and hence molybdenum wire was the primary choice for newlinehigher MRR and lower SR. The MRR obtained for molybdenum wire is newline20.8148, with optimum values of input parameters cutting speed as 75%, Ton newlineas 128 and#956;sec, Toff as 48 and#956;sec, input current as 230 Amps, wire feed as 5 newlinemm/min, wire tension as 7 gms, servo volt as 20 Volts and servo feed rate as newline2086.4 mm/min, for the molybdenum wire, which is relatively higher than the newlinezinc coated and plain brass wires. newline