Investigation of machining parameters and surface integrity in wire electric discharge machining of pure titanium

Abstract

This research work explores the relationship of machining parameters such as pulse on time (Ton), pulse off time (Toff), peak current (Ip), spark gap voltage, wire feed and wire tension on the material removal rate, wire wear ratio and surface roughness for pure titanium in wire electric discharge machining process. The Box–Behnken design had been utilized to plan the experiments, and response surface methodology was employed for developing the empirical models. The peak current, spark gap voltage, pulse on time, pulse off time and interaction between pulse on time and peak current affected the surface roughness significantly. Multi-response optimization of process parameters was obtained using desirability approach. Furthermore, the selected machined samples were analyzed using energy-dispersive X-ray analysis, scanning electron microscope and X-ray diffraction techniques. The predictions from this model were validated by conducting confirmatory experiments.