Synopsis

SYNOPSIS

There are a number of hybrid machining processes (HMPs) seeking the

combined advantage of wire electrical discharge machining (WEDM) and other

machining techniques. One such combination is wire electrical discharge grinding

(WEDG), which is commonly used for micro-machining of fine and hard rods. A special

rotary fixture has been added to a five-axis wire EDM machine to enable generation of

cylindrical geometry.

In this work the objective is to fabricate a electrode of diameter 0.5mm and

aspect ratio 20 using wire electric discharge grinding process in a copper rod of 6mm

initial diameter. The experiment was conducted by varying parameters like voltage, peak

current, pulse off time etc... An experimental analysis was conducted using Taguchi’s

design of experiments ( L16 Orthogonal array ) and the outcome of results were

tabulated. In order to identify the percentage contribution of varies machining parameters

based on the result outcome that influence the diametral accuracy and the material

removal rate (MRR) on the machined parts were obtained using analysis of variance

method (ANOVA). This study has demonstrated that the WEDG process parameters can

be adjusted to achieve either high material removal rate or best diametrical accuracy.

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