Optimization of Wire EDM Parameters for Fabrication of Micro Channels
Wire Electric Discharge Machining (WEDM) is
thermal machining process capable of machining very hard
electrically conductive material irrespective of their hardness.
WEDM is being widely used to machine micro scale parts with the
high dimensional accuracy and surface finish. The objective of this
paper is to optimize the process parameters of wire EDM to fabricate
the micro channels and to calculate the surface finish and material
removal rate of micro channels fabricated using wire EDM. The
material used is aluminum 6061 alloy. The experiments were
performed using CNC wire cut electric discharge machine. The effect
of various parameters of WEDM like pulse on time (TON) with the
levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35,
45) and current (IP) with the levels (105, 110, 115) were investigated
to study the effect on output parameter i.e. Surface Roughness and
Material Removal Rate (MRR). Each experiment was conducted
under different conditions of pulse on time, pulse off time and peak
current. For material removal rate, TON and Ip
were the most significant process parameter. MRR increases with the increase in
TON and Ip and decreases with the increase in TOFF. For surface
roughness, TON and Ip have the maximum effect and TOFF was found
out to be less effective.
[1] R. Chaudhary, R. Rampal, and N. Sharma, “Investigation and
optimization of materiel removal rate for wire cut electro discharge
machining in EN5 steel using response surface methodology,” Int. J.
Lat. Trend. Engg. Techn., vol. 3, no. 1, pp. 192-199, Sep. 2013.
[2] S. M. Son, H. S. Lim, A. S. Kumar, and M. Rahman, “Influences of
pulsed power condition on the machining properties in micro EDM,” J.
Mat. Process. Techn., vol. 190, iss. 1-3, pp. 73-76, July, 2007.
[3] U. Esme, A. Sagbas, and F. Kahraman, “Prediction of surface roughness
in wire electrical discharge machining using design of experiments and
neural networks,” Iranian J. Sci. Techn., Trans. B. Engg., vol. 33, no.
B3, pp. 231-240, 2009.
[4] V. M. Kumar, A. S. Babu, R. Venkatasamy, and M. Raajenthiren,
“Optimization of the WEDM parameters on machining Incoloy800
super alloy with multiple quality characteristics,” Optimization, vol. 2,
iss. 6, pp. 1538-1547, 2010.
[5] M. J. Mir, K. Sheikh, B. Singh, and N. Malhotra, “Modeling and
analysis of machining parameters for surface roughness in powder
mixed EDM using RSM approach,” Int. J. Engg. Sci. Tech., vol. 4, no. 3,
pp. 45-52, 2012.
[6] R. Phipon, and B. B. Pradhan, “Process parameters optimization of
micro electric discharge machining process using genetic algorithm,”
Int. J. Engg. Res. Appl., vol. 2, iss. 5, pp. 1986-1993, Sept.-Oct. 2012.
[7] R. K. Singh, and D. K. Singh, “Control parameters optimization of wire-
EDM by using genetic algorithm,” VSRD Int. J. Mech. Civil Auto. Prod.
Engg., vol. 3, iss. 9, pp. 327-331, Sept. 2013.
[8] S. Lakshmanan, and M. Kumar, “Optimization of EDM parameters
using response surface methodology for EN31 tool steel machining,” Int.
J. Engg. Sci. Innov. Techn., vol. 2, iss. 5, pp. 64-71, Sept. 2013.
[9] S. K. Majhi, M. K. Pradhan, and H. Soni, “Optimization of EDM
parameters using integrated approach of RSM, GRA and entropy
method,” Int. J. Appl. Res. Mech. Engg., vol. 3, iss. 1, pp. 82-87, 2013.
[10] A. Joshi, S. S. Samant, and K. K. S. Mer, “Modelling surface finish in
WEDM using RSM” Int. J. Appl. Res. Mech. Engg., vol. 2, iss. 4, pp.
74-78, 2013.
[1] R. Chaudhary, R. Rampal, and N. Sharma, “Investigation and
optimization of materiel removal rate for wire cut electro discharge
machining in EN5 steel using response surface methodology,” Int. J.
Lat. Trend. Engg. Techn., vol. 3, no. 1, pp. 192-199, Sep. 2013.
[2] S. M. Son, H. S. Lim, A. S. Kumar, and M. Rahman, “Influences of
pulsed power condition on the machining properties in micro EDM,” J.
Mat. Process. Techn., vol. 190, iss. 1-3, pp. 73-76, July, 2007.
[3] U. Esme, A. Sagbas, and F. Kahraman, “Prediction of surface roughness
in wire electrical discharge machining using design of experiments and
neural networks,” Iranian J. Sci. Techn., Trans. B. Engg., vol. 33, no.
B3, pp. 231-240, 2009.
[4] V. M. Kumar, A. S. Babu, R. Venkatasamy, and M. Raajenthiren,
“Optimization of the WEDM parameters on machining Incoloy800
super alloy with multiple quality characteristics,” Optimization, vol. 2,
iss. 6, pp. 1538-1547, 2010.
[5] M. J. Mir, K. Sheikh, B. Singh, and N. Malhotra, “Modeling and
analysis of machining parameters for surface roughness in powder
mixed EDM using RSM approach,” Int. J. Engg. Sci. Tech., vol. 4, no. 3,
pp. 45-52, 2012.
[6] R. Phipon, and B. B. Pradhan, “Process parameters optimization of
micro electric discharge machining process using genetic algorithm,”
Int. J. Engg. Res. Appl., vol. 2, iss. 5, pp. 1986-1993, Sept.-Oct. 2012.
[7] R. K. Singh, and D. K. Singh, “Control parameters optimization of wire-
EDM by using genetic algorithm,” VSRD Int. J. Mech. Civil Auto. Prod.
Engg., vol. 3, iss. 9, pp. 327-331, Sept. 2013.
[8] S. Lakshmanan, and M. Kumar, “Optimization of EDM parameters
using response surface methodology for EN31 tool steel machining,” Int.
J. Engg. Sci. Innov. Techn., vol. 2, iss. 5, pp. 64-71, Sept. 2013.
[9] S. K. Majhi, M. K. Pradhan, and H. Soni, “Optimization of EDM
parameters using integrated approach of RSM, GRA and entropy
method,” Int. J. Appl. Res. Mech. Engg., vol. 3, iss. 1, pp. 82-87, 2013.
[10] A. Joshi, S. S. Samant, and K. K. S. Mer, “Modelling surface finish in
WEDM using RSM” Int. J. Appl. Res. Mech. Engg., vol. 2, iss. 4, pp.
74-78, 2013.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:70970", author = "Gurinder Singh Brar and Sarbjeet Singh and Harry Garg", title = "Optimization of Wire EDM Parameters for Fabrication of Micro Channels", abstract = "Wire Electric Discharge Machining (WEDM) is
thermal machining process capable of machining very hard
electrically conductive material irrespective of their hardness.
WEDM is being widely used to machine micro scale parts with the
high dimensional accuracy and surface finish. The objective of this
paper is to optimize the process parameters of wire EDM to fabricate
the micro channels and to calculate the surface finish and material
removal rate of micro channels fabricated using wire EDM. The
material used is aluminum 6061 alloy. The experiments were
performed using CNC wire cut electric discharge machine. The effect
of various parameters of WEDM like pulse on time (TON) with the
levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35,
45) and current (IP) with the levels (105, 110, 115) were investigated
to study the effect on output parameter i.e. Surface Roughness and
Material Removal Rate (MRR). Each experiment was conducted
under different conditions of pulse on time, pulse off time and peak
current. For material removal rate, TON and Ip
were the most significant process parameter. MRR increases with the increase in
TON and Ip and decreases with the increase in TOFF. For surface
roughness, TON and Ip have the maximum effect and TOFF was found
out to be less effective.", keywords = "Micro Channels, Wire Electric Discharge Machining
(WEDM), Metal Removal Rate (MRR), Surface Finish.", volume = "9", number = "10", pages = "1729-4", }