Experimental investigation on enhancing die corner accuracy during powder mixed wire EDM of Ti6Al4V

• Published in: Materials today : proceedings 2021-01, Vol.38, p.3097-3102
• Main Authors: Chakraborty, Sadananda, Mitra, Souren, Bose, Dipankar
• Format: Article
• Language: English
• Subjects: Die corner error; Parameter modification approach; Powder mixed wire EDM; Productivity
• ISSN: 2214-7853; 2214-7853
• DOI: 10.1016/j.matpr.2020.09.491

•Influence of process parameters on response measures such as corner inaccuracy and MRR.•Powder properties and types mixed with dielectric have significant role on responses.•High discharge energy causes high MRR, as well as reduced surface finish.•Low pulse setting with powder mixed dielectric provides optimum corner accuracy as well as MRR.•Multiple machining operations can be avoided for the final product using powder mixed wire EDM. Owing to increase demand and machining capability, wire electric discharge machining (WEDM) is one of the promising machining processes to make precision geometry specially for dies and machine tools. The present investigation focused on hybridization of the process by integrating power into dielectric to achieve desired die corner accuracy of the ‘hard to cut’ material. The presence of abrasive powder in flushing dielectric considerably improve plasma channel so that better outcome has been achieved. The effect of process parameters, as well as different powders, mixed dielectric has been analyzed on the measured responses such as corner accuracy and metal removal rate to reduce the uncut area in terms of corner error. Obtained results established that adding powder in dielectric enhances the corner accuracy with a proper setting of input parameter. Therefore, 43.66% improvement of corner accuracy is achieved in the proposed hybrid technique. B4C abrasive powder particle mixed with dielectric shows the highest impact on corner error and MRR. Moreover, high discharge energy and the addition of powder in dielectric increase the productivity that is more preferable for manufacture excellent quality of the product with low cost and large quantity. At the same time, the low discharge energy provides better corner accuracy with lower productivity.