Journal of Scientific & Industrial Research

32
Vol. 68, January 2009, pp. 32-35 J SCI IND RES VOL 68 JANUARY 2009

Evaluation of optimal parameters for machining brass with wire cut EDM
C V S Parameswara Rao1* and M M M Sarcar2
1
K L College of Engineering, Vaddeswaram 522 502, India
2
A U College of Engineering, Visakhapatnam 530 001, India

Received 27 February 2008; revised 04 November 2008; accepted 11 November 2008

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.

Keywords: Cutting Speed, Spark gap, Wire material, WEDM

Introduction rectangular slots (4 mm x 6 mm) and L –slots using CNC

Wire-cut electric discharge machine (WEDM) is
used in the field of dies, moulds, precision
manufacturing and contour cutting etc. Any complex
shape can be easily generated with high grade of
accuracy and surface finish using computer numerical
control (CNC) WEDM. Customized software
development has further strengthened process
technology in improving geometrical and technological
data of work piece1-3. An analysis of effects of various
process parameters for achieving improved machining
characteristics is required for successful utilization of
process with high productivity4-8. This study analyzes
effects of process parameters on machining
characteristics of CNC WEDM on different criteria
(cutting speed, surface finish, spark gap, specific energy
consumption) and evolves optimal parameters.
Experimentation
Optimal parameters4,6 that are set on machine before
cutting are as follows: machine, ELCUT 234; dielectric,
de- ionized water; dielectric conductivity, 38 mhos; wire
tension, 80 N; wire velocity, 2.5 m/min; wire diam, 0.25
mm; and gap voltage, 75-80 V. Brass work pieces
(thickness, 5, 10, 20, 40, 60 and 80 mm) were cut with
*Author for correspondence
Tel: 09849291903, 0866-2485151
E-mail: cprao66@yahoo.co.in
part programming. Cuts (4) were performed on each work
piece by altering current. Data for maximum cutting speed
and minimum wire rupture was recorded. Rectangular
slot was tested for surface finish using Taly surf, and L
slots for spark gap using Shadow graph and microscope.
Experiments were repeated on 5 mm thick job with 4
different wires (A, B, C, and D) having following
composition: A, 90% Cu + 10% Zn; B, 85% Cu + 15%
Zn; C, 80% Cu + 20% Zn; and D, 66% Cu + 34% Zn.
Results were tested for fitness with any size of brass work
piece.
Results and Discussion
After setting the job for cutting, wire tension, which
is varied to identify optimal stretched condition without
rupture, is determined as 80 N. Sample tests were
performed under a pre set gap voltage (80 V) to see the
effect of wire velocity on maximum achievable cutting
current. Hence, to optimize process, by varying discharge
current, other criteria are recorded, plotted and analyzed
using Origin 8.0 software. R2 value, standard deviation,
(SD), and error analysis were performed.
Best-fit curve for variation of cutting speed with
respect to thickness of work piece shows curve with
downward slope (Fig. 1). Cutting speed decreases as
thickness of the job increases, may be due to high quantity
of material removal at higher thickness with limited power
 RAO & SARCAR: EVALUATION OF OPTIMAL PARAMETERS FOR MACHINING BRASS WITH WIRE CUT EDM 33

y y
8 80

7 E quation y = A2 + (A1 -A2)/(1 + exp((x-x0)/dx

))

6 Adj. R -S quare 0.98 521

E quation y = A2 + (A1-A2)/(1 + exp((x-x0)/dx))
Value S tandard E rror 60
B A1 22543.1853 3.05 042E 7
Adj. R -S quare 0.98873
B A2 1.03 564 0.12 991
5 Value S tandard E rror

spark gap
B x0 -101.54794 17712.26734
B A1 -34933.44805 1.11976E7
cutting speed

B dx 13.0 6636 3.33 005 B A2 79.07807 1.15783

B x0 -114.5558 5708.18015
4 B dx 17.73232 4.76589

40
3

20
1

0
x
0 10 20 30 40 50 60 70 80
0 x
Thickness
T hicknes s
0 10 20 30 40 50 60 70 80
Fig. 1—Thickness vs cutting speed (R = 0.9851, SD = 0.247) 2 Thickness
T hicknes s

Fig. 2—Effect of thickness on spark gap ( R 2 = 0.99061 , SD=

1.40185)
9
8 90
7 80
5m m
6 10m m 70
Current, amp

5m m
Current, amp

5 20m m 60 10m m
4 40m m
50 20m m
3 60m m
40 40m m
80m m
2
30 60m m
1
80m m
20
0
0 2 4 6 8 10

cutting sp eed 0
cutting speed
0 2 4 6 8

spark gap

Fig. 3—Effect of current on cutting speed

Fig. 4—Effect of current on spark gap

40

35
8
Current, amp

30
Current, amp

5m m
6
C urren t,am p

25 10m m

20
20m m 4
40m m
15 60m m 2
10 80m m
0
5

0
0 50 100
0 2 4 6 8
Thickness, mm
M R R ,m m 3 /m in
spark gap

Fig. 5—Effect of current on MRR Fig. 6—Effect of thickness on current

34 J SCI IND RES VOL 68 JANUARY 2009

35

3.5
30
3

25
2.5

Surface roughness
MRR values

20 E quation y=y0 + (A/(w*sqrt(P I/2)))*exp(-2*((x-xc)/w)^2) 2

Adj. R -S quare 0.87907
Value S tandard E rror 1.5
B y0 -140.4355 1185.27922
15 B xc 48.86379 1.41779
B w 208.01708 755.75639
B A 44141.1763 469264.67291 1
B s igma 104.00854
10 B F W HM 244.92139
B Height 169.31092
0.5

5 0
0 20 40 60 80 100
0 T h ick n e ss,m m
0 10 20 30 40 50 60 70 80 Thickness
Thickness
Fig. 7—Effect of thickness on MRR ( R 2 = 0.89922 , Fig. 8—Effect of thickness on surface finish
SD= 1.6829)

Table 1—Cutting parameters with wires of different composition (work, thickness 5 mm; wire, 0.25 mm brass)

Cu Current Voltage Power Cutting Spark gap MRR Ra Sp.MRR

% I V W speed, Cs mm/1000 mm3/min
mm/min
A90 2.0 78 156 7.6 44 12.84 3.5 0.082
B85 2.0 75 150 7.4 40 12.21 3.0 0.081
C80 2.0 80 160 6.8 39 11.15 2.9 0.069
D66 1.75 78 136 6.2 37 10.04 2.8 0.073

source and current carrying capacity of the wire. R2 this plot (Fig. 6), optimum current can be considered
value (0.9851) and SD (0.247) are obtained. This plot is for any job thickness in working range of machine. By
useful for cutting time estimation,process planning and increasing MRR (Fig. 7), work piece thickness increases
cost estimation. Plot (Fig. 2) of variation of spark gap up to 60 mm and then declines. R2 value (0.89922) and
with increase in thickness is useful for providing offset SD (1.6829) obtained are within permissible limit.
during CNC part programming. Best-fit curve, equation Roughness values decrease with increase in thickness
is obtained using Origin 8.0 soft ware. R2 value and SD (Fig. 8). Wire (90% Cu) gave best results (Table 1) and
are determined and found to be satisfactory. Plot is preferable for higher productivity.
(Fig. 3) to determine effect of discharge current on
cutting speed for different sizes of work pieces tested, Mathematical Relations
gave optimum values of current and cutting speed for Following mathematical relations were developed
stable cutting. For thick jobs (5 mm and 10 mm), using Origin 8.0 software: 1) Cutting speed and work
variation is drastic, whereas for other thicknesses it is piece thickness, Cs=1.0356+ {22542.18/ (1+exp
normal. Plot (Fig. 4) on effect of spark gap with current (T+101.54)/13.06)}; and 2) Spark gap and work piece
for all sizes of work pieces tested, showed an increasing thickness, SG = 79.08-{34854.37/ [1+exp (T+114.55)/
trend in spark gap with current increment. At higher 17.73]}.
current, spark will jump longer distance and may cause
more over cut. Conclusions
Discharge current increases as material removal rate Effect of parameters (discharge current, job
(MRR) increases for different sizes of work pieces thickness, material composition) studied on machining
(Fig. 5). A linear pattern (Fig. 6) of discharge current at criteria (cutting speed, spark gap, MRR) is useful in
optimum value was observed with increase in work piece determining quantification of parameters for quality cuts
thickness under same set of machining conditions. From on brass. Mathematical relations developed are more
 RAO & SARCAR: EVALUATION OF OPTIMAL PARAMETERS FOR MACHINING BRASS WITH WIRE CUT EDM
beneficial to estimate cutting time, cost of machining,
process planning and accuracy of cutting for any size of
job within machine range. Results are useful in
manufacturing wire EDM system for die and tool and
electrodes.
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