Experimental investigation and modeling of wire erosion and surface roughness in wire electrical discharge machine

IV ABSTRACT PhD Thesis EXPERIMENTAL INVESTIGATION AND MODELING OF WIRE EROSION AND SURFACE ROUGHNESS IN WIRE ELECTRICAL DISCHARGE MACHINE Nihat TOSUN Fırat University Graduate School of Natural and Applied Sciences Department of Mechanical Engineering 2001, Page: 107 The important performance characteristics of wire electrical discharge machining are workpiece surface roughness, cutting rate and overcut. A micro scale to investigation of wire electrode erosion and surface roughness of workpiece is required to determine the physics of the performance characteristics. In this study, the variation of the diameter and the depth of the wear craters on the wire are investigated experimentally and theoretically under different puis on time, wire speed, voltage and dielectric flushing pressure. The crater sizes on the wire electrode are measured by using a microscope. The brass wire with diameter of 0.25 mm and SAE 4140 steel as workpiece material have been used in experimental. It is found analysis of variance observed that pulse time and voltage is effective on the crater sizes and the weight loss of the wire and surface roughness of workpiece whereas wire speed and dielectric flushing pressure is not effective. The experimental results have been presented graphically. This work has been compared with other published works and the results are modeled mathematically by using regression analysis method. Key Words: Wire EDM, crater sizes, wire erosion, surface roughness, analysis of variance, regression analysis.