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

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. © © 2024 Inderscience Enterprises Ltd.