WEDM CUTTING PARAMETER OPTIMIZATION BASED ON ROUGHING PRODUCTIVITY AND FINISHING QUALITY

Researcher: Peter FondaPeterFonda.bmp

Start date:    October 2009

End date:      July 2010

Keyword:      PCD micro tools,

                     6-axis wire EDM

Objectives

Improve accuracy.

Abstract

Micro tools are commonly made of extremely hard materials like PCD, where traditional grinding processes cannot be efficiently applied. The wire electrical discharge machine (WEDM) is an ideal means for manufacturing such tooling, due to the ability to cut any conductive material without concern for the material’s hardness. For small workpiece thicknesses, which are on the same order of micro tooling diameters (~0.2mm), the best cutting parameters to achieve high productivity during roughing and fine surface finish with no surface cracking during finishing, are dependent on an operator’s experience level and varies greatly. An experimental design has been made in order to systematically find the optimal WEDMing parameters by employing the Taguchi method to optimize roughing conditions for productivity and finishing conditions for quality.

Poster

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