Investigation of machining characterization for wire wear ratio & MRR on pure titanium in WEDM process through response surface methodology

Abstract

WEDM process is usually used in manufacturing industries to machine electrically conductive materials with complex shapes and varying degree of hardness. This study mainly involves the development of empirical models for wire wear ratio and material removal rate, in terms of six prominent input parameters using response surface methodology. The objective of developing the model is to establish the quantitative relationship between the output and the input control parameters. The effect of significant terms on machined work surface and wear out wire surface topography was analyzed through energy dispersive X-ray analysis and scanning electron microscope techniques. The wire and machined surface topography was deteriorated and appeared in the form of craters, spherical particles, globules of debris and micro-cracks.