ESTIMATION OF MACHINING COST WITH ENHANCED SURFACE FINISH IN WEDM FOR INCONEL 800

Abstract

Wire EDM is a widely used non-conventional machining process in manufacturing industries where precision is the foremost criteria. On the other hand, the decrease in consumable items required to complete the machining process by maintaining the precision level has always been a challenging task for manufacturing industries. The total machining cost for a product is dependent on the machining time taken with respect to the consumption of power, wire electrode and dielectric fluid to complete the machining process. Now, an experimental study, analysis and practical measurements of all the Wire EDM consumables for the machining process has been done to find out the approximate amount of machining cost. This experimental work is projected on the determination of optimum machining parameters with respect to the less machining time and machining cost for best surface finish. The design for the experiment is scheduled by Taguchi’s orthogonal array L18 to cut the workpiece linearly up to 10 mm by means of zinc coated wire. Later on Response optimization method is used to find out the best combination of machining parameters and these machining parameters were validated by using oscilloscope for the justification of the actual units and correctness in time signals (pulse on/ off time).