Optimization of control factors for EN-42 on WEDM using Taguchi method
Pages : 371-376Download PDF
EN-42 offers a variety of advantages over its counterparts such as better stability after hardening, compressive strength, non-deforming properties, and good wear resistance. Due to these properties it is gaining application in manufacturing of laminated spring for railway vehicle, spring washer for used in auto industries, leaf and coil springs. In this study, an attempt has been made to machine EN-42 using wire electric discharge machining. The objective is to investigate the influence of process parameters namely pulse on time; pulse off time, peak current and wire feed on cutting rate and surface roughness. Wire breakage is a problem that constraint the productivity achieved during WEDM process. Wire breakage is directly governed by the discharge energy subjected on the work piece. Discharge energy is influenced by levels of process parameters. Moreover, the influence of process parameters on productivity and accuracy aspects is material dependent. Therefore, preliminary study is carried out to sort out the significant process parameters affecting the cutting rate as well as to identify the operating levels of process parameters. The operating range identified through preliminary study for pulse on time is from 105 μs to 120 μs, pulse off time from 30 μs to 45 μs, peak current from 70A to 130A and wire feed from 6 m/min to 9 m/min respectively. To investigate parametric influence on response parameters, a Taguchi methodology is used to plan and analyze the experiments. The mathematical relationships between WEDM input process parameters and response parameters are established to determine optimal values of cutting rate and surface roughness mathematically
Keywords: WEDM, Energy-saving pulse power, Energy utilization rate, Energy consumption analysis