Effect of Process Parameters in WEDM (Wire Electrical Discharge Machining) Angle Cutting on D3tool Steel Material

Abstract

In Wire Electrical Discharge Machining (WEDM) process, one general practice is Angular-cutting operation. It is adopted in extrusion of dies for the production of complex geometric components - cutting dies, resistant materials etc. The wire is deformed during cutting; consequently there is a fluctuation in angle of inclination of machine parts. This phenomenon leads to inaccuracy in dimensions and losses in tolerance, which causes to reject a high-value-added tool. Statistical designs of experiments were carried to reduce the experimental load. In AISI D3tool the influence of process parameters like cutting angle, part thickness and servo voltage on response parameters like cutting speed, angular error & machining time is studied. Response surface methodology (central composite design) is used for designing experiments and ANOVA (Analysis of variance) was conduct to calculate the influence of every parameter on responses. Regression equation was developed relating responses to the process parameters. Results show that part thickness was the most influencing variable and secondly servo voltage and the least influencing variable was found to be cutting angle.