Title: Comparative analysis of WEDM performance of Nitronic-30 using different wire electrode materials

Authors: Nilesh Tanaji Mohite; Geetanjali Vijay Patil

Addresses: Department of Mechanical Engineering, B.L.D.E.A's V.P. Dr. P.G. Halakatti College of Engineering and Technology, Affiliated to: Visvesvaraya Technological University, Belagavi, Vijayapur, Karnataka, 586103, India ' Department of Mechanical Engineering, B.L.D.E.A's V.P. Dr. P.G. Halakatti College of Engineering and Technology, Affiliated to: Visvesvaraya Technological University, Belagavi, Vijayapur, Karnataka, 586103, India

Abstract: In order to make the machining process sustainable, it is essential to understand the reasons and mechanisms influencing wire failure in order to save machining time and conserve resources. Different electrode materials perform differently due to variations in conductivity, composition, and tensile strength. Thus, a thorough comparative investigation was conducted to understand the impact of zinc-coated wire, diffused wire, and gamma-coated wire during WEDM of Nitronic-30. The investigation involved measuring the material removal rate and surface roughness for different input parameters like pulse on time, pulse off time, peak current, and servo voltage. The findings revealed that zinc-coated wire material was not suitable for machining due to multiple wire breakage incidents. Gamma-coated wire emerged as the ideal candidate, exhibiting a significant improvement in MRR, with 7.38% more compared to zinc-coated wire and 28.84% more compared to diffused wire. Furthermore, economic justification indicated an 18.87% cost saving with the use of gamma-coated wire.

Keywords: gamma coated wire; diffused wire; zinc coated wire; sustainability; Nitronic-30; material removal rate; MRR.

DOI: 10.1504/IJMMM.2023.136035

International Journal of Machining and Machinability of Materials, 2023 Vol.25 No.3/4, pp.375 - 407

Received: 06 May 2023
Accepted: 26 Aug 2023
Published online: 12 Jan 2024 *

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