PERFORMANCE EVALUATION OF WIRE ELECTRO DISCHARGE MACHINING ON SILICON CARBIDE
Keywords:wire electro discharge machining, reaction-bonded silicon carbide, pulse on, pulse off, peak current, servo voltage, surface roughness, sparking gap, cutting speed, design of experiment
AbstractThe machining of reaction-bonded silicon carbide (RBSiC) using wire electro-discharge machining (WEDM) with brass wire diameter of 0.25 mm has been used as the tool electrode. The main purpose of this study was to investigate the influenced of various parameters involved namely pulse on (ON), pulse off (OFF), peak current (IP) and servo voltage (SV) on the machining characteristics, namely surface roughness (Ra), sparking gap (Gap) and cutting speed (CS). The Full Factorial Design of Experiment (DOE) approach with two-level was used to formulate the experimental layout, to analyze the effect of each parameter on the machining characteristics and to predict the optimal setting for each WEDM parameters. Confirmation tests were also conducted for the optimum conditions for each machining characteristics in order to verify and compare the results from the theoretical prediction using Design Expert software and experimental confirmation tests. In general, results revealed that pulse on and peak current have appeared to be the significant effect to all responses investigated. Overall, the results from the confirmation tests showed that the percentage of performance was acceptable due to all the results obtained were within the allowable values which was less than 15% of margin error.
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