Evaluation of optimal parameters for machining brass with wire cut EDM

Abstract

Wire-cut electric discharge machine (WEDM) has been applied for dimensional accuracy, surface finish, and geometric features of work pieces (electrodes, dies etc.) in metal cutting industry. This study evaluates optimal parameters (discharge current, voltage at rated wire speed and tension) for brass electrode (sizes, 5-80 mm). Influence of optimal parameters on cutting speed, surface roughness, spark gap (cutting off-set required) and material removal rate (MRR) is studied. Mathematical relations are obtained for cutting speed, spark gap and MRR. Effect of wire material on cutting criterion is also evaluated for work piece (5 mm thick) using 4 wires of different copper percentages. This study is useful in finding cutting time for any size of job and to set parameters for required surface finish with high accuracy of cutting.