THE EFFECT OF THE PULSE CURRENT IN WIRE ELECTRIC DISCHARGE MACHINE ON MEASUREMENT ERROR TOWARD ALUMINUM ALLOY: AN EXPERIMENTAL STUDY

This research investigates the measurement error on Wire EDM cutting products to find the pulse current's problem-solving. One of the machining parameters that affect the precision of Wire EDM is the magnitude of the current. The experimental study carried out by using the pulse current started from 4-Ampere up to 8-Ampere as the research parameters. A chamfer dimension on 6061 Aluminum alloy was investigated with the gd&t method with ISO 5459 and ISO 1101 standard. Statistic method applied and processed on Minitab with Shapiro-Wilk parameter for normal distribution. These experimental studies have a normal distribution that finds the phenomena of 8-Ampere of pulse current generate a large measurement error. Furthermore, in these experimental studies, the usage of a Profile Projector generates a massive measurement error, up to 64.5% compared with CMM. A strong commitment to calibrate the Profile Projector up to date to maintain the machining quality.

Modeling and Parametric Investigation of WEDM for D-2 Tool Steel Using RSM and GA

Wire Electric Discharge machine is non-conventional thermo-electric spark erosion machining process to cut conductive metal and alloys. The main mechanism of machining is spark erosion between the tool and work-piece. High carbon high chromium tool steel (D-2) is a hard alloy with high hardness and wear resisting property. The purpose of this study is to investigate the effect of process parameters on the machining of D-2 tool steel. D-2 tool steel used in tool and die industries. Response Surface Methodology (RSM) is used to formulate a mathematical model which correlates the independent process parameters with the desired dimensional deviation. The central composite rotatable design has been used to conduct the experiments. Genetic algorithm is used to predict the best individual parameters along with the predicted fitness values.

Study on Machining of Cracking Notches for Automotive Connecting Rod Using WEDM

In order to resolve the problem of connecting rod notches machining, a new process of WEDM (Wire Electric Discharge Machine) has been presented, and it is greatly possible that expensive laser process can be replaced by WEDM in virtue of its unique advantages. Firstly, process parameters of notch have been analyzed, and project of machining notch using WEDM has been introduced, including measures to achieve good-quality notch. The relationship between cutting speed and power supply parameters has been investigated, and it is discovered that micro-crackle on bottom of notch are greatly effect to fracture splitting process, also new idea of active controlling micro-crackle has been presented. Finally, fracture splitting machining has been carried out. The cost and entrance standard of fracture splitting process are greatly dropped owing to new breakthrough of machining notch using WEDM.