Evaluation and improvement in geometric accuracy of components processed using wire cut edm

Abstract

The Wire-cut EDM (WEDM) process is mostly used in die and newlinetool making industry for its distinctive capability of producing twodimensional newlineand three-dimensional profiles with drafted features. In general, newlineWEDM process is meeting the dimensional and other accuracy features newlinerequired by the industry. However, this process has some inherent problems newlinein meeting the requirements of ultra-precision components. In this thesis, newlineinherent geometrical inaccuracies (taper error and corner error) evolved newlineduring the WEDM process are addressed. A set of experiments was conducted to carry out parametric study in taper cutting of AISI D3 tool steel. The taper error, cutting speed and surface roughness were considered as the responses. The influence of the newlinetaper angle on the taper error was investigated. By using Taguchi based grey newlinerelational analysis the optimal solution was reported.The later part of work is focused on improving the die corner accuracy by using the trim cutting strategy. The interesting aspect of this work is that the consideration of the Corner Error (CE) left immediately after the first of the trim cut. The influence of the parametric setting in the first cut newlineon the considered responses, particularly for CE, is elaborately investigated newlineand a lot of fruitful conclusions were drawn. The parametric study was carried newlineout. The trim cutting strategy was found to be superior to the pulse parameter newlinemodification strategy used for enhancing corner accura newline newline