A study to achieve a fine surface finish in Wire-EDM

Many Wire-EDM machines have adopted the pulse-generating circuit using low power for ignition and high power for machining. However, it is not suitable for finishing process since the energy generated by the high-voltage sub-circuit is too high to obtain a desired fine surface, no matter how short the pulse-on time is assigned. For the machine used in this research, the best surface roughness R-a after finishing process is about 0.7 mum. In order to obtain good surface roughness, the traditional circuit using low power for ignition is modified for machining as well. With the assistance of Taguchi quality design, ANOVA and F-test, machining voltage, current-limiting resistance, type of pulse-generating circuit and capacitance are identified as the significant parameters affecting the surface roughness in finishing process. In addition, it is found that a low conductivity of dielectric should be incorporated for the discharge spark to take place. After analyzing the effect of each relevant factor on surface roughness, appropriate values of all parameter are chosen and a fine surface of roughness R-a = 0.22 mum is achieved. The improvement is limited because finishing process becomes more difficult due to the occurrence of short circuit attributed to wire deflection and vibration when the energy is gradually lowered. (C) 2004 Elsevier B.V. All rights reserved.