Modeling of Surface Quality and Wire Offset during WEDM of Die Steel D3

Abstract

The present model portrays the quality of surface machined and wire offset during wire-EDM of Die Steel D3 using zinc-coated brass wire. Taguchi approach is employed, and the orthogonal array was developed using peak current, pulse on duration, and wire tension as the machining parameters. Dependency of wire EDM factors over surface roughness and wire offset was assessed. It was found that the roughness of the machined surface is majorly controlled by on duration of the pulse. For wire offset, the current is the crucial electrical parameter. Higher intensity sparks induce a dimensional shift in the work.