Abstract
Wire electrical discharge machining (WEDM) is one of the promising methods to produce precision dies and machine tools. In the present work, die corner accuracy achievable through trim cutting operation has been analyzed in the presence of a higher wire lag arising due to the higher workpiece thickness, acute corner angle, and higher flushing nozzle height. The influence of the corner error (uncut area left between the actual profile and the desired profile) generated in the first cut (rough cut) on the considered responses, namely volume removal rate, corner accuracy, surface roughness, and dimensional shift, has been analyzed by setting three different parameters during the first cut of the trim cutting operation. It is established that the trim cutting operation is a superior strategy for improving die corner accuracy than the pulse parameter modification strategy. Nevertheless, the high pulse parameter setting in rough cut was preferred for achieving greater productivity while the low pulse parameter setting in rough cut was chosen to achieve better corner accuracy at the cost of lower productivity.
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Selvakumar, G., Bravilin Jiju, K., Sarkar, S. et al. Enhancing die corner accuracy through trim cut in WEDM. Int J Adv Manuf Technol 83, 791–803 (2016). https://doi.org/10.1007/s00170-015-7606-0
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DOI: https://doi.org/10.1007/s00170-015-7606-0