Abstract:
Various techniques employing mechanical, thermal, electrical, chemical, and in some cases a mix of these energies are used in non-conventional machining processes. Wire Electric Discharge Machining (WEDM) is a non-traditional machining technology that removes material by using electricity to generate thermal heat. Every day, the demand for precision in the manufacture of delicate parts grows. Material removal rate, surface finish, and recast thickness are three areas in WEDM that are a focus of research because they are critical in all manufactured parts, especially those made of difficult-to-machine materials such as magnets, tungsten, and ceramics. As a result, this study will concentrate on this topic.
The NdFeB magnet is utilised in this study because it is widely employed in the automobile, defence, aerospace, and hearing devices industries. NdFeB is impossible to machine using traditional production methods. Different sets of machine input settings were used to mill NdFeB magnets on WEDM to see how they affected desired output parameters. In this study, four input parameters, namely voltage, current, pulse-on time, and pulse-off time, are employed in various combinations. The Taguchi method is used to create experimental designs. ANOVA is used for statistical analysis, and the contribution of each input parameter to each output parameter is examined. This made it easier to distinguish between significant and non-significant components. For further mathematical calculations, a regression equation is also established.
The results of the experiments demonstrated that increasing the current and pulse-on duration improves MRR while deteriorating the surface quality and causing a thicker recast layer. Craters appear on the machined surface, and the likelihood of crater formation increases during the WEDM process as the current and pulse-on duration increase. Poor surface smoothness and a thicker recast layer are caused by larger craters on the machined surface. Lowering the EDM machine voltage and reducing the pulse-on time results in a finer surface finish and a smaller recast layer. The pulse on time, current, and voltage have all been found to have a substantial impact on MRR. Recast layer thickness and surface finish. The least influential input parameter in this study is pulse off time.
