Optimization of cutting parameters for zirconium diboride (ZrB2) Using wire cut EDM

摘要

The Wire Electric Discharge Machining is a variation of EDM process and is commonly known as wire-cut EDM or wire cutting. In this process, a thin metallic wire is fed on-to the workpiece, which is submerged in a tank of dielectric fluid. Wire cutting EDM is used when lower residual stresses are desired, because it does not require high cutting forces for removal of material. WEDM has been adopted as a machining tool for die materials which require high strength and hardness as well as good resistance. Rough cutting operation in WEDM is treated as a challenging one because improvement of more than one machining performance measures i.e metal removal rate (MRR), surface finish (SF) and cutting width are sought to obtain a precision work. Using Taguchi's parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration, pulse frequency, wire speed, wire tension, and dielectric flow. The relation between various control factors and responses like MRR, SF are established by means of nonlinear regression analysis, resulting in a valid mathematical model. The paper indicates that the process parameters can be adjusted to achieve better metal removal rate, surface finish and cutting width simultaneously.