Optimization Of Machining Parameters In Wire EDM

Kwan, Chin Seng (2012) Optimization Of Machining Parameters In Wire EDM. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

The objective of this project is to optimize the machining parameters in wire electrical discharge machining (WEDM) in order to machine an electrode with the desirable quality and accuracy. The intended purpose of the electrode is for the application of miniature machining in EDM die-sinking. The machining of small and precision part is problematic due to the presence of high mechanical force in most of the manufacturing processes that might damage or deform the part. The application of electrical discharge to remove material in WEDM is a potential solution to the problem due to the non-contact nature between the electrode and the workpiece during the machining process. Throughout the study, the variable machining parameters such as open circuit voltage, discharge current and voltage gap were investigated. Response surface methodology (RSM) has been used to design the experiment and analyze the results. The quality and accuracy of the electrode were measured on the surface roughness and kerf width, respectively. The significant machining parameters on the surface roughness are open circuit voltage and voltage gap while the significant machining parameter on the kerf width is discharge current. A fine surface roughness of 1.68 J.lm and a small kerf width of 0.271 mm were achieved. The confirmation runs have shown the acceptable percentage of variation between the predicted value and actual value on the surface roughness with 6.52% and kerf width with 2.01%.

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