Effects of process parameters on material removal rate in WEDM

Purpose: In this paper, the effects of various process parameters of WEDM like pulse on time (TON), pulse off time (TOFF), gap voltage (SV), peak current (IP), wire feed (WF) and wire tension (WT) have been investigated to reveal their impact on material removal rate of hot die steel (H-11) using one variable at a time approach. The optimal set of process parameters has also been predicted to maximize the material removal rate. Design/methodology/approach: The experimental studies were performed on ELECTRONICA SPRINTCUT WEDM machine. Findings: The material removal rate (MRR) directly increases with increase in pulse on time (TON) and peak current (IP) while decreases with increase in pulse off time (TOFF) and servo voltage (SV). Practical implications: Wire electrical discharge machining (WEDM) is a specialized thermal machining process capable of accurately machining parts which have varying hardness, complex shapes and sharp edges that are very difficult to be machined by the traditional machining processes. The practical technology of the WEDM process is based on the conventional EDM sparking phenomenon utilizing the widely accepted noncontact technique of material removal. Originality/value: We can say that the wire feed and wire tension are neutral input parameters.