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International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 11, November 2018, pp. 908–921, Article ID: IJMET_09_11_092

Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=11

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

A STUDY ON WIRE ELECTRIC DISCHARGE

MACHINING PROCESS PARAMETERS

*P.S.Gowthaman, J.Gowthaman, P.Athisankar

Assistant Professor, Department of Mechanical Engineering,

P.S.N.A College of Engineering and Technology, Dindigul, Tamil Nadu, India.

ABSTRACT

In a fastest Technology the future of the industries demands the materials have much

superior properties as high strength, low weight and withstand the temperature. It is

difficult to machine by conventional machining methods. Wire electric Discharge

machining is a variation of EDM Process it is known as wire cutting. It is commonly used

to make a complex shape and micro machining. WEDM decrease the productivity,

increase the economic cutting speed and requires much superior quality of tool materials.

It machined a Stainless steel, super alloys, High temperature resistant materials and

composites. The process can also cut a plates as thickness 300mm and it is used for

making punches, making tools, dies from hard materials. They produce complex shapes,

Better surface finish, Low tolerance and Higher MRR. WEDM is used in the many areas

of Aerospace, medical, electronics, Semiconductor, Tool die making industries, in making

Fixtures, gauges, cams cutting of gear strippers, manufacturing hard electrodes. These

paper reviews the contribution of various researchers in wire electric discharge

machining. In addition literature survey, utilization of tools and techniques for

correlating experimental results has been concluded.

Keywords: Wire electric Discharge machining, Tool die making industries, Aerospace,

medical, electronics

Cite this Article: P.S.Gowthaman, J.Gowthaman and P.Athisankar, a Study on Wire

Electric Discharge Machining Process Parameters, International Journal of Mechanical

Engineering and Technology, 9(11), 2018, pp. 908–921.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=11

1. INTRODUCTION

The first CNC Controlled Wire electric discharge machining (WEDM) was invented by

Theologian in 1976. WEDM is an electro-thermal production process in which single thin strand

metal wire conjunction with deionized water (used to conduct electricity) allows the wire to cut

through the materials by the use of heat from electrical sparks. In a Wire electric discharge

machining a wire about (0.05-0.30mm diameter) is used as an electrode and deionized water as a

materials. In Wire electric discharge thin strand metal wire brass is fed through the work piece.

The wire is fed from spool which is held guided between upper and lower side. The guide moves

on X-Y axis. Sometimes upper guide moves independently through rise the transitioning shape

P.S.Gowthaman, J.Gowthaman and P.Athisankar


(circle on bottom square on the top). Electrodes are connected to the pulsed DC supply. A

constant gap is maintained between the tool and work piece .Heat is generated due to the sparking

result in the melting of work piece and wire material and sometimes the part of the WEDM is

composed four basic elements of this machine tool as Power supply system, Dielectric system,

wire feed system, positioning system.

Figure.1 Principle of WEDM

2. LITERATURE REVIEW

R.A Kapgate (2015) et al. They investigates and develop the model using dimensional analysis

to determine the MRR for Triangular, circular and rectangular shape cut on Al/Sic 10%

experiment was done on CNC WEDM with brass as electrode wire of 0.25mm.In these they

develop the mathematical model for different shapes to help to maximize the use of Al/Sic/MMC

for higher performance.

Kunag-Yuan Kung (2009) et al. In these work various input parameters are selected to

evaluate their effect on MRR The work depend as on Pulse time and peak current increases means

the MRR also increases.

C.D Shah (2014) et al. These paper deals the optimization of process parameters of WEDM

during machining Inconel 600 using RSM. Four parameters were considered as pulse on time,

pulse off time, peak current, wire feed rate were chosen to study their effect experimentally on

the performance response of material removal rate. Taguchi with mixed L18 array is used for

optimization and ANOVA is used for analysis and RSM is used to develop the surface models

for parameters. Results indicate the effect of pulse on Time and peak current has significant effect

on MRR.

MA Hassan (2009) et al. They outlines the effect on surface integrity of AISI 4140 steel in

WEDM. In these Experiment surface texture was analysed by SEM. Model of WEDM is used a

brass wire. Taguchi orthogonal array is used for design of experiment .The result indicates Pulse

duration has a major effect in determining the surface texture in compared with pulse current.

The work shows a high discharge energy creates the larger melting of work piece and deeper

formation of crater and surface finish is poor.

Nitin Kumar (2012) et al. They found the effect of cutting parameters on wear depth of brass

wire of TI 60G12Alloy steel. In these work pixel image study is used for analysing the electrode

wear on the surface roughness through different images. Taguchi orthogonal array along with

ANOVA test was conducted to study the effect of parameters on crater depth and kerf width.

These work determines the contribution of wire feed, spark voltage are maximum effect on the

work piece and result shows the increase in MRR.

A Study on Wire Electric Discharge Machining Process Parameters


Y.B.Guo (2013) et al. This study focus on the effect of discharge energy on the surface

integrity from main and Trim cuts. EDM analysis is conceded out to determine surface

topography to show coral reef microstructure at high discharge and random micro voids are in

low discharge energy. Thick layers(8.3-13.3µm) are discontinuously and non uniform at relative

high energy. Trim cut at low energy is continuous and free of micro voids. White layers have

reduction in microhardness test which indicates significant thermal degradation occur in

discharge energy. Surface alloying can be minimized by reduce the discharge energy in finish of

Trim cuts.

T.Wang (2013) et al. This paper used the new developed technology of dry wire electric

discharge machining. The process explore the processing mechanism of dry WEDM. The studies

shows the single pulse discharge mechanism in gas with finite element method. In the thermal

field analysing the radius and depth of the crater in gas generated by single pulse is stimulated.

In field analysis The temperature distribution is calculate in thermal analysis was applied in load.

The Simulation results indicates the crater generate in gas is larger in diameter and smaller in

depth because of surface finish.

Eberhard Bamberg (2008) et al. This paper investigates the WEDM of Gallium doped P-

Type Germanium with relaxation type pulse generator. Experiments were performed to

established the slicing rate for different size of electrical wires .Samples are analysed using 3-

DProfile projector and SEM. All the samples are etched and analysed for contamination using

the X-ray Energy dispersive spectrometer. The maximum discharge energy is used in Germanium

and no sub surface damage is obtained. The phenomenon of increase in slicing rate with increase

in wire diameter is shown in higher discharge energy.

K.K Choi (2008) et al. These paper describes the effect of heat treatment (Tempering) on

Die steel STD11. The surface machined WEDM using four different machining methods as

milling and grinding, WEDM, Low temperature heat treatment, High temperature heat treatment

after WEDM. In general heat treatment after WEDM shows the improve in quality of

microstructure and surface roughness. Similarly high temperature Tempering remove the entire

defect in thermally affected zone. WEDM and High temperature Tempering Microstructure effect

shows the top surface and side surface are completely differ from the other samples.

Pan Huijun (2103) et al. This study shows the influence of small holes on heat transfer

process in mono-crystalline silicone is machined by WEDM. The results shows the small holes

make the surface surface heat treatment change towards body heat source. More thermal stress

damage is happen and crack propagation depth is increased. During the silicon cut it appears after

the discharge pulse power density achieves a certain value.

Shanthanu shahane (2016) et al. In these work author developed the Finite element model

(FEM) in WEDM .To compute the temperature distribution in the workpiece and MRR. These

noval approach shows the overlap effect of multiple sparks and experimental results. The study

determines the process parameters relation with MRR. Model is validated from the both single

and multiple spark results. Compare the both results in the relation of MRR with Process

parameters. The proposed model results shows the multiple spark model closer to the MRR and

same in the single spark.

K.Mouralava (2016) et al. This study analyse the surface machining of 16MnCr15 steel in

WEDM using Minitab and It influence the cutting speed on the quantitative and qualitative

evaluation of crater formation. Using brass wire it measure the wear rate and chemical

composition.an analysis indicate no amount of crack detect in the high speed cut. Using EDX

analysis and exhibits the copper and zinc and melted part. Microstructure analysis determines the

70% of region in intensive diffusion processed. The profile parameters of the samples detected

the mean value of surface roughness.



H.Gotoh (2013) et al. This paper shows the new developed method combining the WEDM

and ED-Milling It named as WEDM milling. In this process the wire guide with hemispherical

tip is used and grooved is prepared on the surface. Wire guide is reciprocated in the rotary state

and move along the desired path and it generate the 3D shape it is similar to ball end mill.

V.Parashar (2012) et al. This paper shows the experiments were performed on Taguchi

orthogonal array. Every Sample they analyse the MRR. ANOVA is used for find the variables in

the parameters. The variations on MRR are modelled using Regression method.

3. EXPERIMENTAL PARAMETERS

WEDM is an important technology which needs a high speed cutting and high speed machining

and improved the accuracy of machined hard materials. It has experience the explosive growth

and complexity of equipments as well as raising the demand for basic tool. In general cutting

performance of WEDM depends upon the combination of electrical, mechanical, physical and

geometrical properties of wire electrode.

Figure. 2 CNC Controlled WEDM

WEDM is basically composed of wire drive unit and two axes feed system. Thus the several

craters were generated on the surface of the workpiece and measured separately. Following

parameters are used in the wire electric discharge machining.

3.1. Pulse on Time

The Pulse on Time is actual time electrical discharge is occurs between the work piece and

electrode wire and voltage is apply in same manner. For need a long discharge need a long value

of on time is selected. Higher value describes the breakage of wire.

3.2. Pulse off time

During the Pulse off time no voltage is passed no electrical discharge consequently take place

between the work piece and wire electrode .Using low value of discharge means It cause the wire

breakage and cutting efficiency also reduces.

3.3. Peak current

Peak current is the maximum amount of current flowing through the circuit during pulse on time.

The parameter reveals how much power is used in the WEDM. Power supply system basically in



pulse frequency it results in reduced crater size or better surface finish. However a small size wire

it usually cannot carry current more than 20A.High value is required for roughing operations and

cutting rate is also increases because of increase in peak current.

3.4. Servo Voltage

Servo voltage is an important parameters used in the machining. The parameter really controls

the movement of wire. Servo voltage is more the gap between the wire electrode and work piece

will be wider and hence electric spark will be less and machining rate will be low. Servo voltage

is less means the gap is also less so the electric spark are more then automatically machining and

the cutting rate will be more.

3.5. Wire Tension

This parameter reveals about the straightness movement of the electrode wire. This shows if the

wire tension is high then wire will remain straight, otherwise drag or bent take place in the

machining. Properties of the wire have an impact on MRR and quality of cut surface. Normally

brass, zinc and molybdenum wire is used for machining. The wire is once and then scrapped

because it gets eroded. A wire can carry heavier load and it can absorb more amount of heat

without breaking. A heavier load means more amount of energy release and higher MRR results

higher cutting speed.

3.6. Wire Speed

This is an important factor which deals the actual speed movement of wire in WEDM. If speed

is more, than the consumption of wire will be more and speed is less means wire breakage is

occur. It continuously delivers the fresh wire and always keep in tension so that moves in the

machining zone as straight wire. A Wire drive system minimize the sire break during the

machining.

3.7. Dielectric Fluid

Dielectric fluid is an essential parameters in WEDM. It is used to dissipate the heat and cool the

wire and flush off the re-solidified particles from the gap. Commonly used Dielectric fluid for

machining is Distilled water oil. Water is substitute for kerosene as dielectric in Electric discharge

machining. It gives a higher MRR and higher finish in identical conditions. More efficient way

of dielectric delivery is to provide a stream of deionized water along the axis of the wire.

4. PROCESS PARAMETERS

The Experiment of WEDM is tried to use in different condition by many authors ,To improve the

quality and performance measures of electric discharge like Cutting speed, MRR, Surface

roughness, Kerf width, wire ratio, wire-lag, So that the machining rate, productivity, accuracy of

WEDM can be improved. Hence the selection of optimal machining parameters play role to

obtain higher cutting speed, higher surface finish.



Figure.3. Machining Zone

4.1. Material Removal Rate (MRR)

The material removal rate is a significant parameter which affects the productivity.MRR is the

amount of material remove from the work piece under the working time. It defines the

characteristics efficiency of machine. In hard materials MRR is significantly influences on the

discharge current. From the literature it was found that the higher MRR can be achieve by the

positive polarity of the electrode with kerosene as a dielectric fluid. The Material removal is

increased with increase in discharge current due to strengthened discharge energy melts and

remove the material easily. It depends upon the electrode material, melting temperature and

electrode wear rate. The MRR is directly proportional to the discharge pulse energy. on the other

hand pulse energy depend upon the voltage. Hardness and melting temperature affects the MRR.

Material with high melting temperature and high thermal conductivity cause more heat transfer

of discharge energy hence the lower MRR is attained. The variation of MRR with respect to

control the parameters. It was observed the MRR is increases with increased pulse on time,

whereas the MRR decreases with increase the servo voltage and pulse off time[12].When increase

the flushing pressure leads to spilling out relatively more amount of molten material thus lead to

higher MRR..High pressure cause unfavourable sparking conditions due to wire vibration and

deflection, thus affecting the spark intensity with lower material removal rate[13].The rate of

cutting speed with Zinc coated wire is higher than the brass. In fact the addition of Zinc to brass

leads to reduction in wire melting point. The low melting temperature of wire improves the spark

formation and decrease the dielectric zone that increase MRR[14].The pulse duration and

discharge current significantly affect the MRR, Higher MRR is achieved by increase the pulse

duration due to the accumulated energy discharge melts and evaporates the material. The thermal

energy of the spark cause the intense heat condition of workpiece[15].Okka et al. Discuss the

effect of single and multi channel electrodes on MRR made on copper and brass. Single channel

shows higher MRR. the flushing cleans the discharge gap and reduce the frequency and results

indicate less removal of material and brass is more efficient to obtain Higher MRR and does not

absorb much heat. Gua et al, the effect of TIi-6Al-4V alloy with bundle die sinking electrode

performance compared with solid die sinking electrode. During machining both shows increases

in MRR. At the higher current (>57A), MRR decrease with the solid electrode at the peak current

of(63A).The gap determines insulation effect of dielectric medium to unstable discharge of

limited flushing. Lin et al[16] Study the MRR combined EDM with kerosene and deionized water

with Sic abrasive concentration as dielectrics. Thus the abrasive enhance The gap between the

electrode and work piece cause the Higher MRR. Rajaneesh et al[12] investigates the

performance of WEDM in Sic particles Al-Zn alloys .In this work the pulse on time and peak

current are varied according to the samples and indicates the MRR decreases the reason of Sic

particles increased in the composite. Also MMR increases the pulse duration.



4.2. Surface Integrity

It is an intrinsic factor that affect the machining condition. The major contributing factor is the

main of processing action. It comprise the surface roughness, surface morphology, residual stress

and white layer formation. The surface is machined by unconventional means have less defects,

fine surface finish, no plastic deformation, residual stress. The component is used for the majority

of micro fabrication and good quality is required. The properties of material changes due to plastic

deformation of grain size in Ti based alloy. Moreover no significant decarburizing occurs due to

the intrinsically low carbon content of the investigate super alloy, The microstructure appears

unaltered by the WEDM machining despite the high thermal gradient experienced by the material.

The outer layer in Inconel material is recast one formed by the molten metal solidifying. The

grains are highlighted by the etching performed prior to the SEM [6].

Figure.4. Relationship between surface roughness and Pulse duration (Source: Rev. adv. Mater. Sci

2014, 89-111)

Table 1 Materials used and contribution

Author

Year

Material

machined

Tool

material

Contribution

Yan

(2009)

et al

Ti-6AL-4V

and NAK

steel

Brass

wire

Developed

appropriate

method for fine

finish power

supply in WEDM

and Applications

is studied.

Hsieh(2

009)et

al

Titanium

alloy and

Tungsten

carbide

Brass

wire

WEDM

characteristics of

TiNix Ternary

shape memory

alloys is studied.

Kuriako

se

(2003)

et al

Titanium

alloy

Zinc

coated

brass

wire

The data mining

approach is

obtained to

decide the

optimum

parameters.

Sarkar(

2010)

et.al

Ti-6al-4V and

Titanium

Aluminde

Brass

wire

They presented

integral approach

to optimize the

WEDM of

Titanium

aluminde.



Bamber

g(2008)

et al

Tool steel,

Titanium

alloy and

tungsten

carbide.

Brass

and

molybd

enum

wire

WEDM machined

samples are

modelled by

ANIFS method.

PujariR

ao(2010

)et al

Al 24345

alloy

Brass

Wire

ANOVA and

Taguchi method

is used to

evaluate the

optimum

parameters.

.Aspinw

all(2008

)et al

Inconel 718

Zinc

coated

brass

Investigate the

recast layer

thickness which

is 11µm during

the machining of

inconel and

eliminate the

etching.

Antar(2

011)et

al

Ti-6Al-2Sn-

4zr-6Mo and

udimet 720

nickel based

super alloys

Copper

wire

with

zinc

coating

They studied the

effect of wire

electrode on the

productivity,

surface roughness

and residual

stress.

Weinga

rtner(20

13) et al

- Brass

wire

A Thermo

electrical model

is developed to

understand the

higher melting

efficiencies and

as relative speed

Yan

(2007)

et al

Titanium and

tool steel Brass

Developed a high

frequency power

supply for surface

quality

improvement.

4.3. Surface Roughness

It is an important parameter that influence the performance of the machined component and

depend upon the contact between the surfaces and friction. The surface deviation characteristics

is used for the calculation of Roughness[14].The surface roughness is mainly varied by pulse

duration because of the selection of tool material in Ti-6Al-4v.The surface of the machined

component increase the discharge means increased the spark .Discharge current and impulsive

force leads to higher crater formation. The crater in the workpiece of high electric fluid leads to

higher surface roughness and higher spark is occurred sometimes detrition take place. Higher

servo speed produce good surface finish and material removal rate due to the erosion of material

take place. Decrease in surface roughness leads to Increased in pulse off voltage. It may be due

to the sufficient long to acquire uniform erosion. The longer pulse off produce the cooling effect

of material and remove the debris particle in the processing chamber. In order to achieve good

finish means increase the longer pulse off time with high discharge current.



Figure.5 Crater formation of machined surface in Ti-6Al-4V (Source: Rev. adv. Mater. Sci 2014, 89-

111)

If the wire speed is lower, the melting of the material is more due to higher energy and

significantly higher MRR causes the higher surface roughness. Therefore the optimum wire speed

is important need for the better surface finish. Similarly wire tension because the vibration during

the cutting and higher wire tension is subjected to breakage. The machine feed also affects the

roughness which in turn the wire tension and voltage significantly affects the surface roughness

because of wire vibration and strong electric field discharge the spark at the same gap between

the electrode and the work piece induces the coarse surface.

4.4. Surface Topography

The surface texture is depend upon the mechanical properties of work piece and the machining

conditions. Topography surface at the lower duty factor is appeared as a higher duty factor. It is

observed the profile has more peaks and valleys at 50% duty factor. The higher temperature

causes the elevated arcing and slight damage to the tool of the electrode .In these process author

achieved the higher surface roughness during the machining of titanium (Ti6Al4V) alloy and no

recast layer is obtained in the surface.

Figure.6 Surface topography plot of current-400A,-1.8µs.

The SEM photograph determines the titanium alloy with different electric fluids. The

kerosene is used due to high thermal conductivity and higher cooling rate of distilled

water .Kerosene as the dielectric medium causes the more noticeable cracks in the machined

surface.

4.5. Layer formation

The surface layer if formed due to the re-solidification of melted material at high temperature.

The machined surface is categorized as a white layer, which is surface layer below the white layer

cat layer and heat affected zone is present. It is essential to understand the machine layer and



minimize the thickness. Formation of layer due to the insufficient servo voltage, pulse duration

and discharge current. The evaluation of layer formation is based on the discharge current,

dielectric fluid and flushing pressure. In the machining process the surface exhibits the property

entirely different from the bulk material property. The white cast layer hardness is extremely

higher than the bulk material layer, This is brittle in nature and easy to undergo the crack in

machined surface, It is also affects the surface quality and fatigue property of material. Many

authors investigate the formation of recast layer in Ti based alloys. In the surface conditions

white layer formation is less, when distilled water is used as dielectric fluid compared to kerosene

in Figure-6.Further increase pulse duration increased the white layer thickness. Because more

melting and production of debris re-solidification of machined surface. The cooling rate is more

in distilled water compared in kerosene due to heat generation in molten material rapidly transfers

into dielectric distilled water. The additives in the dielectric cause the reduction of layer thickness

compare to pure dielectric. additives play the major role to flush the molten metal from the

machined surface[16].

The effect of peak current on recast layer increased with increase in peak current irrespective

of dielectric medium. The effect of peak current produce the recast layer thickness around 11mm

and produce the deeper and larger craters consequently melts more amount of material and

solidifies the machined surface. The 3d Surface topography of WEDM shows the random

distributed craters. The machined surface shows the coral reef microstructure due to debris may

be resolidified from the vaporized material or splashed molten material by rapid water quenching.

during the discharge the presence of large volume of gas in the channel will lead to higher super

saturation of gas in molten pool. while the remaining material solidifies on the surface, gas

bubbles would expel the molten material, As the discharge energy decrease means more molten

metal would not be swept away but solidifies on surface.

Figure. 7 3D-Topographic map at different discharge energy (Source: Rev. adv. Mater. Sci 2014, 89-

111)



The increase in the pulse duration increase the layer thickness, Even though the effect of

dielectric medium cause the reduction of recast layer thickness. The EDM assist USM completely

removes the debris and the motel metal from the machined surface unlikely in the conventional

process. The EDM surface contains enriched carbon, chemical alterations. It is possible for

machining optimum tool and selection of material.

4.6. Residual Stress

It is distributed due to the in homogenous temperature distribution and quenching effect by the

dielectric fluid. Retained stress after the plastic deformation in the machined work piece,

contributing to tensile stresses in the subsurface of the material. It alters the microstructure of the

underlying material subjected to the high temperature. Cracks formation due the thermal stresses

at the machining condition of pulse on the duration of48µsand the peak current of 3A.The cracks

are originated in the blow hole and formation of white layer in the region. This is due to higher

pulse duration and thermal stresses. The copper material with zinc layer coating generates the

low residual stress compared to brass wire. Residual stresses are reduce the fatigue life of the

components.

The tensile stresses are originate the crack in the recast layer thickness and penetrates in to

the bulk material when the stress outgrips the tensile strength of the material. The stresses

increases due to the rapid heating and cooling of the material by the dielectric fluid. The residual

stresses produce the poor fatigue strength. It is eliminated in heat treatment condition. The

machined surface contains, micro cracks, blow holes, melted droplets, debris and substantial

layers, these may be deviate to residual stress distribution extent. The machined surface of Ti Ni

and Ti-Ni-Cu alloy were hardness is increased from 200 to 750 Hv. Due to the formation of

oxides TiO2 TiNiO3 and debris in the recast layer. Hardness is varied from outer to inner depth

surface. The machined surface hardness is varied as dielectric fluid because of solidification of

molten metal at very high temperature and machined surface. Yan shows the effect of machined

surface hardness is high when the use of urea solution in dielectric fluid in titanium alloy and

high voltage causes the increases the microhardness up to the depth of 5µm.

7. MODELING TECHNIQUES

Researchers studied their experiment with the input parameters using the modelling techniques

and present the model for the output responses from the input parameters. The optimization

responses are employed using technique such as ANN, Fuzzy logic, Factorial design, Genetic

algorithm, Particle swarm optimization. The thermal area such as FEM based models as

Ansys, CFD, LS Dyna, Deform 3D and so on used for the residual stress, wire breakage,

recast layer with the combination of input parameters. The tools of software gives a good result

with very less errors. Some experiments done EDM/WEDM on real time simulation and online

pulse train analysis system. Tomura et al [17] analyse the electromagnetic force in WEDM using

2Dfinite element methods. Some authors involved in selection of optimization methods in multi

response. To predict the output methods as MRR, TWR and surface roughness using the design

of experiments factorial design and mathematical models were developed.

Researchers suggest the effect of online process analysis and power supply circuit for WEDM

to achieve a better surface finish. Apart from the investigation few authors have studied have

studied the thermal analysis using FEM and developed the mathematical model. The researchers

use the techniques to optimize the process parameters respect to input response.

In the Table 2 Various tools and techniques used in WEDM and related with the experimental

work. Some of the Authors have studied the effect of online process analysis and supply circuit

for WEDM. The other process used for optimization side is computational system for process



design, Tabu search hybrid model, mixed orthogonal array, Artifical bee colony algorithm,

teaching learning based algorithm.

Moreover the researchers used the technique to optimize and predict the MRR, EW, Surface

roughness and cutting velocity in WEDM. The finite based result is necessary for thermal related

works in WEDM. The authors used analyse and predict the recast layer, temperature

redistribution and residual stress appeared in WEDM Surface. The finite element model is also

used to prevent the wire breakage. The surface roughness is an important output in WEDM white

layer thickness was predicted using Neuro-fuzzy interference based full factorial design

experimentation

Table ii process and techniques used

Author Year

Proce

ss

Optimization Techniques

Tarang (1994)

et al.

WED

M

Developed Neural

network and applied to

determine optimal

cutting parameters

Liao(1997)et

al.

WED

M

Proposed the optimal

WEDM machining

parameters based on

Taguchi Technique

Speeding(1997

) et al.

WED

M

They attempted to

optimize the process

parameters using ANN

Bannarje(1997

) et al.

WED

M

Proposed the model

convection to wires

stability.

Sanchez(2004)

et al

WED

M

Numerical simulation

model is developing for

developed the corner

cutting

Sarkar(2005)et

al.

WED

M

Artifical neural network

is used to model the

machining process

Han(2007)et

al.

WED

M

Thermal analysis is

carried out by using

FEM

Ali(2008] et al. WED

M

A Statistical model is

used to achieve high

surface finish andDOE

Technique is applied.

Dodun(2009]

et al.

WED

M

Generated the

mathematical model to

evaluate the loss of

height and contour angle

Haddad(2009)

et al.

WED

M

Responsesurface

methodology is used to

determine MRR.



Okada(2009)et

al.

WED

M

Computional fluid

dynamics is used to

determine the debris

motion

Porous(2009)et

al.

WED

M

Dimensional analysis is

used to create semi

empirical model of the

efficiency of EDM

Liao(2009) et

al.

WED

M

Developed the online

analysis system to

investigate the ignition

delay time in WEDM

Chen(2010) et

al

WED

M

Back propoga.tion neural

network and simulated

annealing algorthim

Janardhan and

samual(2010)

et al.

WED

T

They analysed the effect

of machining parameters

on MRR, Surface

roughness using the

pulse train data acquired

with acquisition system.

Sarkar(2011)

et al.

WED

M

Analytical model is

developed to determine

the gap force

8. CONCLUSION

Based on the literature survey there is lot of research work is progressed in WEDM. But there is

need to study the effect of WEDM in different alloys According to the parameters in the

machining as surface roughness, MRR, recast layer, Residual stress and topographical aspects.

From the aspects of tools and techniques they used for analysis and optimization purposes in

WEDM. It plays a minor role but still research gap. On the other side various tools and technique

is co-relating the experimental results as ANN, Fuzzy logic, Tabu based enhanced algorithm. The

study of surface integrity of advanced material has been investigate by researchers. Authors

Reviewed the important aspects on investigate the machined properties of advanced materials

affected by the input parameters and the other constituents. Moreover researchers focused on Ti-

based alloy, Ni-based alloy depend upon the application. Few of the activities take place in

composite material. Based on the literature it can explore in many fields as mould, die making,

bio medical industries and Precision manufacturing. They precisely in manner exhibits the

versatility in miniaturization of components.



REFERENCES

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[2] K.Mouralava(2016), Analyzing the surface layer after WEDM depending on the parameters

of a machine for the 16MnCr5 steel,International journal of measurements,94,771-779.

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manuf Tech,395.vol 47.

[14] Ulat caydal[2009],Expert system in applications, 6135.

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Tech,48,557.

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