Study Of Sharp Edge Cutting In Wire EDM

Nur Zahirah , Zakria@Zakaria (2009) Study Of Sharp Edge Cutting In Wire EDM. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Wire electrical discharge machining (WEDM) is a thermal machining process by the usage of an electrode to begin the sparking process. During the WEDM process, the material is eroded ahead of the wire and there is no direct contact between the workpiece and the wire which could eliminate the mechanical stresses during machining. The utilizing of continuous traveling wire electrode enables this machine to machining parts with varying hardness or complex shapes accurately. However, due to varying factors like wire tension, wire speed, angle of cut, open-circuit voltage, current, dielectric flow and so on, WEDM could not achieve the accurate dimension during machining especially when cutting the sharp edge at a particular angle. Thus, this study is conducted to finds out the best optimum conditions using WEDM machine (Mitsubishi RA90) in Universiti Teknikal Malaysia Melaka (UTeM) to fabricate high quality products in terms of surface roughness, sharp edge angle and dimensional accuracy. A triangle shape that contains 30o and 120o angle is cut on a mild steel plate to analyze the performance parameters characteristics under different machining conditions or design parameters that have been selected. All the performance parameters are tested using suitable measurement equipment. The surface roughness tester is equipment used to measure the texture of the sample surface. The dimensional accuracy will be measured using optical comparator and meanwhile the accuracy of sharp edge error is analyzed using digital imaging and measurement system. Then, all the data are collected in tables and graphs form to ease the process of data interpretation.

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