Comparative analysis of WEDM performance of Nitronic-30 using different wire electrode materials
by Nilesh Tanaji Mohite; Geetanjali Vijay Patil
International Journal of Machining and Machinability of Materials (IJMMM), Vol. 25, No. 3/4, 2023

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.

Online publication date: Fri, 12-Jan-2024

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