A comparative exploration on numerical and experimental modelling and optimization of material removal rate in wire cut EDM for EN-19 steel alloy

Abstract

At present scenario the demand for compact, integrated and small size products by a non-traditional process is increased because it gives high accuracy. Machining performance specifications of concern include minimum feature size, tolerance, surface finish, and material removal rate (MRR) and applications of advanced, which is very difficult to machine the materials. Wire cut EDM is an important manufacturing process that meets these demands and it has been widely used in production, aerospace/aircraft, medical, and virtually in all areas of conductive material machining. In the present research work, EN-19 steel alloy is used as work material. Experimentation on WEDM is conducted for modelling the material removal rate. The experimental results are used for determining the more dominant parameter on material removal rate (MRR) using optimization techniques. A numerical analysis is carried out using experimental conditions. In this, a model of work is analyzed and theoretical material removal rate is estimated using finite element analysis (FEA). A comparative study is made between the numerical and experimental results.