Investigation of manufacturing micro components using wire electric discharge grinding WEDG process in hard metals

Abstract

Over the decades machining of hard metals has always been a challenge in some manufacturing sectors Hence the introduction of the hybrid machining process was developed and research carried out in the area everywhere Industry prefers manufacture of smaller as a part of development in every field This research focuses on the micro machining of hard metals and investigates with the use of various designs of experiment techniques for material removal rate diameter accuracy and surface roughness In order to do this a rotary accessory setup is designed and fabricated to carry out the micro machining on hard and tough to machine materials The amount of wire deflection was analyzed with the designed numerical model and the variation was found within 25µm For micro machining of high speed steel the spark gap with percentage contribution of 50 and spindle speed with percentage contribution of 24 have great influence on diametric accuracy The spark gap with percentage contribution of 81 has a substantial influence on the material removal rate For micro machining of tungsten spindle speed is the most dominating parameter for diameter accuracy with a percentage contribution of 434The most dominating parameter for material removal rate is the spindle speed with a percentage contribution of 301 and the second parameter is pulse off time with a percentage contribution of 284 newline