Experimental Studies and Development of Empirical Relations for Machining HC-HCr Steel with CNC W E D M

The WEDM has been found to have tremendous potential in its applicability in the present day metal cutting industry for achieving improved dimensional accuracy, surface finish, geometric features of work pieces (electrodes, dies etc.). However for successful utilization of process, optimization of various parameters is required for improving the productivity. In this regard an attempt was made to evaluate optimal parameters like discharge current, voltage at rated wire speed, tension, for different sizes of the prominent Die material, High Carbon-High Chromium steel. (HC-HCr tool steel) ranging from 5mm to 80mm. This work expresses the effects of the above mentioned process parameters on the criteria like cutting speed, surface roughness, spark gap (cutting off-set required) and specific energy consumption. The optimum values are evaluated at uninterrupted machining conditions with minimum wire rupture and breakage. Mathematical relations are explored at the optimum values for determining the cutting speed. Present work is useful in finding the cutting time for any size of the HC-HCr job and to set parameters for the required surface finish, corner radius with high accuracy of cutting.