Optimisation of Microscopic Defects of Wire Electrical Discharge Machining Using ANOVA Response Optimiser
DOI:
https://doi.org/10.15282/Keywords:
Crater width, Pulse on time, Open voltage, Recast layer, Surface Roughness, Wire electrical discharge machiningAbstract
Wire Electrical Discharge Machining (WEDM) employs the principle of electro-thermal discharge, utilising an electric current applied to a wire to generate heat. The process entails liquefying the workpiece material, then vaporising it, and expelling the vaporised material with a dielectric fluid. The research investigates the microscopic characteristics and surface integrity resulting from WEDM of heat-treated high-carbon alloy steel, providing critical insights for precision manufacturing applications. Buderus 2080 high-carbon steel, heat-treated to a hardness of 801 VHN, was machined using WEDM. This research systematically varied pulse-on time (0.2, 0.4, 0.6 µs) and open voltage (75, 90, 105 V) as independent parameters. Surface roughness, recast layer thickness, recast layer hardness and crater width were evaluated as dependent variables. A General Linear Model Factorial as experimental design and Analysis of Variance (ANOVA) were utilised to ascertain the contribution of each independent variable. The findings indicate a direct proportional relationship between pulse-on time and open voltage on the one hand and surface roughness, recast layer thickness and crater width on the other hand. Conversely, a reciprocal proportionality is observed between pulse-on time and the recast layer hardness. Pulse-on time exerted a stronger influence on all dependent variables than open voltage. Optimal machining conditions, determined using the Variance (ANOVA) response optimiser, were a pulse-on time of 0.4µs and an open voltage of 90V.
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