Influence of Machine Feed Rate in WEDM With Constant Current (8A) Using Brass Wire On Titanium Ti-6Al-4V

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Volume 1, Issue 5, May 2017 Available at: www.dbpublications.org
International e-Journal For Technology And Research-2017
Influence of Machine feed rate in WEDM

with constant current (8A) using Brass wire
on Titanium Ti-6Al-4V.
Dr.T.Vijaya Babu1,a* , Dr .J.S Soni 2,b
1
Professor ,Department of Mechanical Engineering, Vardhaman College of Engineering , Shamshabad , Hyderabad, India
2,
Professor & Principal, Bharat Institute of Engineering and Technology , Ibrahimpatnam , Hyderabad, India
a* b
tirividhivijaybabu@gmail.com , drjssoni@yahoo.com
Abstract: Wire electrical discharge machining Keywords: Wire Electrical Discharge Machine
(WEDM) technology has been widely used in the (WEDM),Surface Topography, Material Removal
field of medical, mould making, aerospace and Rate(MRR) , Surface Roughness (SR).
automobile industries. It is a non-traditional machining
process which used the continuously circulating wire 1. INTRODUCTION
as electrode and cuts the work piece along a Wire electrical discharge machining (WEDM) is
programmed path. Improper electrical parameters broadly used in machining of materials when
settings can affect the processing efficiency and
precision is of major factor. WEDM is an ideal
surface roughness due to arcing phenomenon that lead
by discharge point of focus. Objective of the paper is means for manufacturing such tooling because its
to uncover the influence of two different machine rates ability to cut any conductive material regardless
which are 2 mm/min, 4 mm/min with constant current
of hardness. The productivity of fabricating micro
(8A) with WEDM of Titanium Ti-6Al-4V.The results
on kerf width, material removal rate and surface tools can be increased with the use of WEDM
roughness are graphically tabulated. The best technology where more intricate tool geometries
combination of machining parameter viz. machine can be created with high quality. Material is
feed rate (4 mm/min), wire speed (8 m/min), wire
tension (1.4kg) and voltage (60V) were identified. The eroded by series of discrete sparks between the
selection of parameters depends on the requirements work piece and a tool electrode (small wire)
based on a better surface roughness or a maximum immersed in a liquid dielectric medium (deionized
material removal rate. Hence an appropriate
water). These electrical discharges melt and
combination of variables can be selected accordingly.
Furthermore, this combination can contributes to vaporize diminutive amounts of the work
increase production rates perceptibly by reducing material, which are then ejected and flushed away
machining time. The paper highlights the importance
by the dielectric. Since, the work piece and the
of process parameters and different machining
conditions on kerf width, MRR, surface roughness electrode do not have mechanical contact,
(Ra) and surface topography. conductive material regardless of their hardness
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and toughness can be machined by WEDM . It Brass wire is widely used in WEDM processes
consume a continuously travelling wire electrode due to its good machining properties and can be die-
made of thin brass, copper or coated wire of casted or extruded for specialized application. The
diameter 0.050.3mm which is capable to ideal wire electrode material for this process has three
achieve very small corner radii and competency to important criteria i.e high electrical conductivity,
machine precise, complex and irregular shape sufficient mechanical strength and optimum sparks
with high degree of accuracy and fine surface and flushes characteristics.
finish. Titanium Ti-6Al-4V has become very Dielectric
popular materials and widely used as implants for Work pieces that are totally submerged in a tank
dental, restorations and orthodontic wires, as well filled with dielectric fluid grants temperature
as orthopedic due to their low density, high stabilization and efficient flushing especially when the
corrosion resistance and excellent mechanical work piece has varying thickness in WEDM process .
properties. However these alloys were very WEDM used deionised water instead of hydrocarbon
difficult to fabricate as they are not ductile and oil as the dielectric fluid due to its low viscosity and
have low fracture toughness at room temperature . rapid cooling rate .
The paper focused on the importance of kerf Parameter Setting
width, MRR, surface roughness (Ra) and surface The experiment were performed at three different
topography and their strong dependence on the machine feed rate with constant current, wire speed,
input parameters carried out on Titanium Ti-6Al- wire tension and voltage as shown in Table 1.
4V. Experime Experimen Experimen
Parameter
Materials and Methods nt 1 t2 t3
Work material Machine feed 2 4 6

rate(mm/min)
Titanium Ti-6Al-4V has enormous importance in the
Current (A) 8 8 8
aerospace industries. It reduces aircraft weight since
Wire speed
the excellent strength-to-weight ratio and causes a 8 8 8
(m/min)
reduction in fuel consumption and emissions.
Wire tension
Titanium is replacing aluminum in many applications 1.4 1.4 1.4
(Kg)
.Titanium alloys are among the hardest materials to cut
because of poor thermal conductivity, strength at high Voltage (V) 60 60 60
temperatures and chemical reactivity with tool

materials. Table 1 Parameter setting
Wire electrode

Sample Preparation and Experimental Procedure
All specimens were cleaned in an alcohol bath

and then dried specimen Dryer in blower mode. After
that, the specimens were kept in Buehler Specimen
Cabinet Storage to prevent the formation of oxide on
the surface. Titanium Ti-6Al-4V work pieces are cut
into the desired size using Wirecut EDM Mitsubishi
Machine in the presence of dielectric fluid with
addition of anti rust agent liquid to reduce the surface
rust. The kerf is measured the sum of the wire
diameter and twice wirework piece gap. The kerf
value was expressed in three different spot and each
spot will give ten readings, the average of these
Fig 1: Pictorial view of WEDM machine tool
reading will be taken as kerf width. The material
removal rate (MRR) will be calculated using equation Result and Discussions
(1) this equation.
Kerf width
MRR = FX D w X H (1)
The lowest value of machine feed rate give smallest
kerf width. Meanwhile, it can be seen clearly that
F is the machine feed rate [mm/min], Dw is wire
medium setting of machine feed rate gives the average
diameter [mm] and H is piecework thickness [mm]
value of kerf width and high setting of machine feed
and MRR is material removal rate [mm3 /min].
rate applied offered the widest value of kerf width.
F is the machine feed rate [mm/min], Dw is wire

KERFWIDTH
diameter [mm] and H is piecework thickness [mm]
1.95
and MRR is material removal rate [mm3 /min].
1.9 1.93
kerf width(mm)
1.9
1.85 1.88
1.85
1.8
1 2 3 4
Machine feed rate (mm/min)

Fig 2: Result on kerf width of different machine feed

rate SR
1.94
Surface roughness ( m)
Material Removal Rate (MRR)
1.92 1.93
1.9
It was found that with the increasing of machine feed
1.88 1.9
rate, the MRR will increases simultaneously . From 1.88
1.86
the examination of the contour plot, it is noticed that SR
1.84 1.85
MRR increases with increase in feed rate. 1.82
Theoretically, material erosion is influenced by the 1.8
spark energy. As feed rate increase; MRR also 1 2 3 4
increases till it reaches optimum. The MRR decreased Machine feed rate (mm/min)
with the decreasing of machine feed rate.
Fig 4: Result on Surface roughness of different
MRR machine feed rate
10 8 Surface Topography
material removal rate
8 6
6 4
(mm3/min)
There are many factors which make machined surface

4 2
topography have the characteristics of complex and
2 MRF
0 irregular, and impact using performance of parts due
1 2 3 4
to its complicated process. The surface topography of
MRF 2 4 6 8
each experiment under microscope with 100
Machine feed rate(mm/min)
magnification. It shows that low machine feed rate
gives bigger crater compared to high feed rate and
Fig 3: Result on mrr at different machine feed rate vice versa.
Surface Roughness (R a)
Surface roughness (Ra) is an element in measuring

surface quality. It is one of the important factor in
machining because it can predict the performance.
Fig.4 enlightens that smoother surface can be obtained
with low setting of machine feed rate.

2mm/min Machining (WEDM). Int J Mach Tools Manufacturing

44:12471259
[2] D. Rakwal and E. Bamberg, 2009, Slicing,
Cleaning and Kerf Analysis of Germanium Wafers
Machined by Wire Electrical Discharge Machining.
Mater. Process. Technol. 209(8), p 37403751
[3] Sadiq MA, Rahman M, Lim HS, 2008, Study of
WEDM parameter phenomena for micro fabrication.
Int J Manuf Technol Manag 13(24):226240
[4] Miller SF, Kao C-C, Shih AJ, Qu J., 2005,
4mm/min
Investigation of wire electrical discharge machining of
Fig 5: Topography view of different machine feed
thin cross-sections and compliant mechanisms. Int J
rate
Mach Tools Manuf 45:17171725
[5] Qu AJ Shih, RO S., 2002, Development of the
CONCLUSION
cylindrical wire electrical discharge machining
In this paper, an effort was made to determine the process: part : concept, design and material removal
important machining parameters for the performance rate. ASME J Manuf Sci Eng 124(3):702707
of WEDM viz.kerf width, MRR and SR. The main [6] Qu AJ Shih, RO S., 2002, Development of the
goal is the maximum MRR with the minimum kerf cylindrical wire electrical discharge machining
and surface roughness in setting the machining process: part : surface integrity and roundness. J
parameters. Factors machine feed rate have been found Manuf Sci Eng 124(4):708714 [7] Bradley, E.F.,
to play an important role in this experimental work. 1988, Super alloys: A technical guide, ASM
The outcome of this study will help in improving the International.
quality of Titanium Ti-6Al-4V products as well as [8] Ezugwu, E.O., Da Silva, R.B., Bonney, J.,
minimizing the machining cost to realize the Machado, A.R., 2005, Evaluation of the performance
economical potential to the fullest. of CBN tools when turning Ti6Al4V alloy with
high pressure coolant supplies, International Journal of
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Influence of Machine Feed Rate in WEDM With Constant Current (8A) Using Brass Wire On Titanium Ti-6Al-4V

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Influence of Machine Feed Rate in WEDM With Constant Current (8A) Using Brass Wire On Titanium Ti-6Al-4V

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International e-Journal For Technology And Research-2017