Papers by Author: Jatinder Kapoor

Abstract: In this paper, the effect of different wire electrodes used in wire electrical discharge machining (WEDM) on the machining characteristics of AISI D3 die steel has been presented. Three process parameters, namely type of wire (brass wire, zinc coated wire and composite wire), pulse on time and peak current have been considered. The process performance is measured in terms of cutting speed and surface roughness. The research outcome will identify the important parameters and their effect on performance characteristics while machining AISI D3 material with different wire electrodes. The analysis of variance (ANOVA) of multilevel factorial design indicated that all the selected parameters have significant effect on the performance characteristics. The study indicated the improvement in surface roughness with brass wire over other wires. Maximum cutting speed was obtained with composite wire as compared to zinc coated and brass wire. Additionally, scanning electron microscope (SEM) examination highlighted important features of machined work piece surface.

Abstract: The wire electrical discharge machining (WEDM) is widely used for machining workpieces having complex geometries. A wire electrode of diameter 0.25 mm is moved coaxially between two guides and electrical energy in the form of electrical pulses is applied to remove material from the workpiece. In this study, the effect of key process parameters on wire wear of shallow cryogenic treated brass wire electrode used in WEDM was investigated experimentally. Five process parameters, namely Type of wire, Pulse width, Time between two pulses, Wire tension and Servo reference voltage have been considered. Taguchi experimental design has been applied to investigate the optimal parameters for minimum wire wear ratio (WWR). The experimental results indicate that Type of wire; Pulse width and Time between two pulses have a significant effect on WWR. The analysis of variance of mean and analysis of variance of S/N ratio on data was performed to identify the significant factors in order to establish the relative significance of parameters for WWR. It is found experimentally that shallow cryogenic treatment decreases the WWR. Increasing pulse width increases the WWR, where as increasing Time between two pulses decreases WWR. The results have been validated by three confirmation runs for optimum WWR.