DETERMINE THE PROCESS PARAMETERS OF MACHINING OF GEAR ON ELECTRICAL DISCHARGE MACHINING

Mechanical Engineering

Micro-wire EDM is an emerging technology in the field of Micro-machining to fabricate very complex micro products. This is used in the fields of dies, molds; precision manufacturing and contour cutting etc. any complex shape can be generated with high grade of accuracy and surface finish using CNC WEDM. The output of the process is affected by large no of input variables. Hence a suitable selection of input variables for the wire electrical discharge machining (WEDM) process depends heavily on the operator’s technology & experience. In the present investigation an optimization of micro wire EDM has been carried out using Taguchi method. Using taguchi's parameter design, significant machining parameters affecting the performance measures are identified as pulse off time, pulse on time, and current and optimal parameter setting is proposed. The effect of each control factor on the performance measure i.e. surface roughness, addendum circle, root circle, nose radius is studied individually using the plots of signal to noise ratio and analysis of variance. This work presents an experimental study in which wire EDM operations are performed on material SS-304 Steel plate. The effect of three machining parameters namely pulse on time, pulse off time and current are investigated. Trial run was conducted to establish the range of selected parameters. Subsequently pulse on time at three level , pulse off time at three levels and current at three levels are considered and 9 experiments as per the experimental plan of Taguchi’s experimental design i.e. L9 OA are conducted . Five response variable namely Surface roughness, addendum circle, root circle, angle between top land and tooth face, and angle between bottom land and flank are measured. Signal to noise ratio for each response variable are computed. Subsequently, analysis of variance is used to obtain the percentage contribution of the parameters. The analysis of mean is performed to obtain optimum level of the machining parameters for multi performance characteristics. Analysis of variance is used to determine which machining parameters is significantly affected the multi performance characteristics and also to obtain the percentage contribution of each machining parameters towards the objective.

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