EFFECT OF PROCESS PARAMETERS OF MACHINING IN CNC WIRE-CUT EDM FOR ALUMINIUM

The objective of this present work is to investigate the effect of input process parameters of wire electrical discharge machining (WEDM) on aluminium, which are now widely used in many Aerospace, Automotive, Marine, Rail, Building, Mechanical industries. The tool material damages the work piece due to chipping, presence of burrs. Wire cut Electrical discharge machining technique is a thermo electrical process capable of machining complex shapes and any hardness of conductive materials which are difficult to machine with traditional machining methods. As a part of the present research work, aluminium is to be machined in wire cut EDM machine and the effect of five process parameters such as pulse on time (Ton), pulse off time (Toff), wire feed rate, table feed and servo voltage on Material removal rate and surface roughness is to be investigated. The experimental plan is based on Taguchi method using five factors each at three levels. The experiment was done with aluminium material of diameter 0.25 mm. Total no of 27 experiments were performed. Different graphs were plotted to observe the effect of the input parameters on output parameters such as Material Removal Rate, Surface roughness. It was concluded that highest material removal rate was 21.164 mm3/min which was due to high pulse on time and table feed and low pulse off time and servo voltage. Low surface roughness was 2.555 μm which was due to low pulse on time, pulse off time, table feed, wire feed rate and high servo voltage.