Title: Performance of profile characteristics at different machining parameters during wire electric discharge slant type taper profiling on Nicrofer 4722

Authors: Itagi Vijayakumar Manoj; Narendranath SannaYellappa

Addresses: Department of Mechanical Engineering, Nitte Meenakshi Institute of Technology, Bengaluru, Karnataka 560064, India ' Department of Mechanical Engineering, National Institute of Technology Karnataka Surathkal, Karnataka 575025, India

Abstract: In the present study, a slant type taper fixture is employed to achieve taper machining by wire electric discharge machining. Machining parameters like wire distance between the guides (WD), wire offset (WO), corner-dwell time (CT) and cutting-speed override (CO) is used to produce tapered components at 0°, 15°, and 30° angles. It is observed that as the WD, CO and WO increases the profile roughness also increases. The profiling error (PE) increases with increasing WD and CO parameters due to the increase in wire lag phenomenon. However, the WO and CT parameters showed a decreasing effect on PE. There is a reduction observed in the recast layer thickness, as the taper angle increased. The apex of the triangular profile always tends to be shifted opposite to the wire direction of travel at 15° and 30° tapered components due to the electromagnetic force and decreased strength of the tapered corners.

Keywords: slant type fixture; WEDM; profile roughness; profiling error; PE; corner shift; recast layer thickness; micro-hardness.

DOI: 10.1504/IJMMM.2024.139060

International Journal of Machining and Machinability of Materials, 2024 Vol.26 No.2, pp.131 - 148

Received: 13 Jul 2022
Accepted: 11 Oct 2022
Published online: 10 Jun 2024 *

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