Experimental Study and Development of Mathemtical Relations for Machining Copper Using CNC WDEDM

DOI : http://dx.doi.org/10.13005/msri/050222

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Although WEDM has revolutionized the present day metal cutting, die making, press tool and precision manufacturing industries, further improvements are still required to meet the increasing demand of product precision and accuracy in those sectors of manufacturing. The machining performance is greatly influenced by various factors like work material, work thickness, discharge current. This paper briefs the effect of work piece thickness on various cutting parameters like discharge current, cutting speed and performance such as material removal rate, spark gap, when copper is machined. An attempt is made to establish mathematical relations between the work piece thickness and other cutting parameters experimental data. It includes the statistical analysis to determine the square of correlation factor, R2 and Standard deviation values. The mathematical relations are developed using Origin 8.0 software for the best fit curve from the experimental data and ANOVA analysis is applied for analyzing the errors. The results are checked for validation and are found to be encouraging. The mathematical equations explored can be used to establish the machine parameters and estimation of machining time.

WEDM; Cutting speed; MRR; Spark gap; Mathematical relations